Flame retardant coating agent for vehicle seat, and manufacturing method for flame retardant vehicle seat material

ABSTRACT

Provided is a flame-retardant coating agent for vehicle seats that contains (A) a nitrogen-containing compound, and (C) an aqueous thermoplastic resin. Also provided is a flame-retardant vehicle seat material that does not use a halogen compound or an antimony compound, that exhibits sufficient flame retardancy, and that suppresses the occurrence of marks from hot water.

TECHNICAL FIELD

The present invention relates to a flame-retardant coating agent for avehicle seat, and a process for producing a flame-retardant vehicle seatmaterial which has been treated with the coating agent.

BACKGROUND ART

Hitherto, in the field of flame-retardant coating processing on avehicle seat material, such as automotive seat material and railcar seatmaterial, there have been used resin compounds containing ahalogen-based compound typified by decabromodiphenyl ether blendedtherein, or an antimony-based compound typified by antimony trioxideblended therein.

In recent years, in view of environmental concerns, it is demanded touse a flame retarder (i.e., flame-retardant agent) other than thehalogen-based compounds or the antimony-based compound, and accordingly,there are used phosphorus-based flame retarders having no melting point,typified by ammonium polyphosphate (APP), metal hydroxides such asaluminum hydroxide and magnesium hydroxide, phosphoric acid esters, etc.

In the vehicle seat material, the flame retardancy thereof is anessential performance for saving the life of a passenger. Accordingly,the use of a flame retarder having a “better” flame retardancy isindispensable, but it is pointed out that the above-mentioned metalhydroxides and phosphoric acid esters exhibit a flame retardancy whichis inferior to that of the APP. In addition, the use of an organicphosphorus-based flame retarder has a problem of increasing the cost.

On the other hand, APP incurs a low cost while exhibiting a good flameretardancy and therefore, APP is widely used. However, APP is soluble inwater and brings about a problem that water spotting or slime may becaused due to the steam treatment at the time of vehicle seatprocessing, so as to reduce the workability thereof. Herein, the “waterspotting” means a phenomenon that, when a seat having water or steamwhich has been attached thereto after treatment, is dried, the portionto which the water or steam has been attached may be spotted, form acircular stain or be powdered.

In order to solve such a problem, Japanese Unexamined Patent Publication(JP-A, KOKAI) No. 2006-028488 (Patent Document 1) discloses a coatingcomposition for a vehicle interior material, comprising: a syntheticresin emulsion in an amount of 100 mass parts (i.e., parts by mass) interms of solid content; and 1 to 300 mass parts of one kind or two ormore kinds of a non-halogen-based flame retarder added thereto, whereinthe non-halogen-based flame retarder has been obtained by coating thesurfaces of non-halogen-based flame retarder particles containingphosphorus and nitrogen, with a functional group-containingorganosilicon resin. In addition, JP-A No. 2006-063125 (Patent Document2) discloses a process comprising: preparing a composition of apolyphosphate-based flame-retardant from a polyphosphoric acid compoundand a silicone-based resin; and blending the composition with anelastomer resin; and applying the resultant blend to flame-retardanttreatment of a fiber product.

However, it is technically difficult to completely coat APP.Accordingly, the solubility of APP in water may be reduced by themethods according to Patent documents 1 and 2, it has been difficult forthese methods to reduce the solubility of APP in water at hightemperature, particularly, in hot water at 80° C. or more.

As the method using no halogen-based compound, JP-A No. 2006-233152(Patent Document 3) discloses a flame-retardant fabric, which hasattained formaldehyde emission in an amount of 0.1 ppm or less, andcomprises: a fabric and a back coating layer of a back coating agentdisposed on the surface of one side of the fabric, wherein the backcoating agent comprises an acrylic-type copolymer resin having nomethylol group in the acrylic monomer thereof; ammonium polyphosphate, aphosphoric acid ester, and a thickener in a specific ratio.

However, in the method according to Patent Document 3, the problem ofAPP solubility in water has not been solved yet.

In order to make the water spotting unnoticeable, for example, a certainmethod is practiced such that the thickness of cloth (vehicle seatmaterial) is increased, or the design or color tone is devised. However,in this case, the weight of the cloth may be inevitably increased, or acertain restriction may be imposed on the design or decorative propertyof the cloth. Accordingly, there is demanded a non-halogen-basedflame-retardant coating agent for a vehicle seat, which does not requirethe measures as mentioned above, and realizes a reduction in weight of acloth, and also realizes a wide range of design or decorative propertiesof the cloth, to thereby achieve both of an excellent flame retardancyand suppression of the occurrence of water spotting in thenon-halogen-based flame-retardant coating agent for a vehicle seat.

RELATED ART Patent Document

Patent Document 1: JP-A No. 2006-028488

Patent Document 2: JP-A No. 2006-063125

Patent Document 3: JP-A No. 2006-233152

SUMMARY OF THE INVENTION Problems to be Solved by the Invention

The present invention has been made in view of the current circumstancesas mentioned above. Accordingly, an object of the present invention isto provide a flame-retardant vehicle seat material which is capable ofdeveloping sufficient flame retardancy and of suppressing the occurrenceof water spotting by hot water, without using a halogen compound or anantimony compound.

Means for Solving the Problem

As a result of earnest study, the present inventors have found that theuse of a flame-retardant coating agent for a vehicle seat, containing aspecific nitrogen-containing compound and a specific thermoplasticresin, can attain a flame-retardant vehicle seat material which isexcellent in the flame retardancy and is prevented from the occurrenceof water spotting by hot water. The present invention has beenaccomplished based on such a discovery.

One aspect (a) of the present invention can provide a flame-retardantcoating agent for a vehicle seat, which comprises: (A) anitrogen-containing compound and (C) a thermoplastic resin.

The present invention can also provide a flame-retardant coating agentfor a vehicle seat, which comprises: (A) a nitrogen-containing compound,(C) an aqueous thermoplastic resin, and (B) a phosphorus-based compound,and/or (D) a metal hydroxide.

The present invention may include, for example, the followingembodiments.

[a1] A flame-retardant coating agent for a vehicle seat, comprising: (A)a nitrogen-comprising: compound and (C) an aqueous thermoplastic resin.

[a2] A flame-retardant coating agent for a vehicle seat, comprising: (A)a nitrogen-containing compound, (C) an aqueous thermoplastic resin, (B)a phosphorus-based compound, and/or (D) a metal hydroxide.

[a3] The flame-retardant coating agent for a vehicle seat according toeither one of [a1] and [2], wherein Compound (A) is at least one kindselected from the group consisting of melamine compounds, triazinecompounds, and a salt thereof with (iso)cyanuric acid.

[a4] The flame-retardant coating agent for a vehicle seat according toeither one of [a2] and [3], wherein Compound (B) is at least one kindselected from the group consisting of the compounds represented by thefollowing formulae (1) to (5) and a polyphosphoric acid compound andCompound (D) is at least one kind selected from the group consisting ofaluminum hydroxide, magnesium hydroxide and calcium hydroxide:

Formula (1):

(wherein each of R¹ and R² independently represents a phenyl group thatmay have an alkyl group having a carbon number of 1 to 4, a naphthylgroup that may have an alkyl group having a carbon number of 1 to 4, ora biphenyl group that may have an alkyl group having a carbon number of1 to 4, E represents a direct bond, —O— or —N(H)—, “a” represents 1 or2, and b represents 0 or 1);

Formula (2)

(wherein R¹ represents a benzyl group, a methylbenzyl group, a phenethylgroup, a naphthylmethyl group, or a group represented by the followingformula (6)):

Formula (6):

(wherein R⁴ represents an alkyl group having a carbon number of 1 to 10,a phenyl group, or a benzyl group);

Formula (3):

(wherein each of R⁵ to R⁸ independently represents a phenyl group thatmay have an alkyl group having a carbon number of 1 to 4, R⁹ representsan arylene group that may have a substituent, and c represents aninteger of 1 to 5);

Formula (4):

(wherein each of R¹⁰ and R¹¹ independently represents an alkyl grouphaving a carbon number of 1 to 4, and R¹² represents a biphenyl group ora naphthyl group); and

Formula (5):

(wherein each of R¹³ to R¹⁶ independently represents an alkyl grouphaving a carbon number of 1 to 4).

[a5] The flame-retardant coating agent for a vehicle seat according toany one of [a1] to [a4], wherein Compound (C) is a polyurethane resinhaving an anionic group.

[a6] The flame-retardant coating agent for a vehicle seat according toany one of [a2] to [a5], wherein the mixing ratio (A):{(B)+(D)} ofCompound (A) to the total of Compound (B) and Compound (D) is, in massratio, 1:0.1 to 15 and the mixing ratio {(A)+(B)+(D)}:(C) of the totalof Compound (A), Compound (B) and Compound (D) to Compound (C) is, inmass ratio, 1:9 to 9.5:0.5.

[a7] A process for producing a flame-retardant vehicle seat material,comprising treating one surface of a vehicle seat material with theflame-retardant coating agent for a vehicle seat according to any one of[a1] and [a3] to [a6] and then drying it to form a flame-retardant filmcomprising: Compound (A) and Compound (C) on the treated surface of thevehicle seat material and/or in the vehicle seat material, to therebyobtain a flame-retardant vehicle seat material.

[a8] A process for producing a flame-retardant vehicle seat material,comprising treating one surface of a vehicle seat material with theflame-retardant coating agent for a vehicle seat according to any one of[a2] to [a6] and then drying it to form a flame-retardant filmcomprising: Compound (A), Compound (C), Compound (B) and/or Compound (D)on the treated surface of the vehicle seat material and/or in thevehicle seat material, to thereby obtain a flame-retardant vehicle seatmaterial.

According to another aspect (b) of the present invention, there isprovided a flame-retardant coating agent for a vehicle seat, whichcomprises: (A) a nitrogen-containing compound, (B) a phosphorus-basedcompound, and (C) an aqueous thermoplastic resin.

The “aspect (b)” of the present invention may include, for example, thefollowing embodiments.

[b1] A flame-retardant coating agent for a vehicle seat, containing (A)a nitrogen-containing compound, (B) a phosphorus-based compound, and (C)an aqueous thermoplastic resin.

[b2] The flame-retardant coating agent for a vehicle seat according to[b1], wherein Compound (A) is at least one kind selected from the groupconsisting of a melamine compound, a triazine compound, and a saltthereof with an (iso)cyanuric acid.

[b3] The flame-retardant coating agent for a vehicle seat according to[b1] or [b2], wherein Compound (B) is at least one kind selected fromthe group consisting of the compounds represented by the followingformulae (1) to (5) and a polyphosphoric acid compound:

Formula (1):

(wherein each of R¹ and R² independently represents a phenyl group thatmay have an alkyl group having a carbon number of 1 to 4, a naphthylgroup that may have an alkyl group having a carbon number of 1 to 4, ora biphenyl group that may have an alkyl group having a carbon number of1 to 4, B represents a direct bond, —O— or —N(H)—, a represents 1 or 2,and b represents 0 or 1);

Formula (2)

(wherein R³ represents a benzyl group, a methylbenzyl group, a phenethylgroup, a naphthylmethyl group, or a group represented by the followingformula (6)):

Formula (6):

(wherein R⁴ represents an alkyl group having a carbon number of 1 to 10,a phenyl group, or a benzyl group);

Formula (3):

(wherein each of R⁵ to R⁶ independently represents a phenyl group thatmay have an alkyl group having a carbon number of 1 to 4, R⁹ representsan arylene group that may have a substituent, and c represents aninteger of 1 to 5);

Formula (4):

(wherein each of R¹⁰ and R¹¹ independently represents an alkyl grouphaving a carbon number of 1 to 4, and R¹² represents a biphenyl group ora naphthyl group); and

Formula (5):

(wherein each of R¹³ to R¹⁶ independently represents an alkyl grouphaving a carbon number of 1 to 4).

[b4] The flame-retardant coating agent for a vehicle seat according toany one of [b1] to [b3], wherein Compound (C) is a polyurethane resinhaving an anionic group.

[b5] The flame-retardant coating agent for a vehicle seat according toany one of [b1] to [b4], wherein the mixing ratio (A):(B) of Compound(A) to Compound (B) is, in mass ratio, 1:0.1 to 10, and the mixing ratio(A)+(B):(C) of the total of Compound (A) and Compound (B) to Compound(C) is, in mass ratio, 3:7 to 9:1.

[b6] A process for producing a flame-retardant vehicle seat material,including treating one surface of a vehicle seat material with theflame-retardant coating agent for a vehicle seat according to any one of[b1] to [b5], and drying it to form a flame-retardant film containingCompound (A), Compound (B), and Compound (C) on the treated surface ofthe vehicle seat material and/or in the vehicle seat material, tothereby obtain a flame-retardant vehicle seat material.

In the above-mentioned “another aspect” of the present invention, themixing ratio (A):(B) of Compound (A) to Compound (B) in theflame-retardant coating agent for a vehicle seat of the presentinvention may be preferably, in mass ratio, 1:0.1 to 10, more preferably1:0.1 to 7, still more preferably 1:0.1 to 5. Outside this range, theflame retardancy may tend to be reduced.

In the above-mentioned “another aspect b” of the present invention, themixing ratio (A)+(B):(C) of the total of Compound (A) and Compound (B)to Compound (C) may be preferably, in mass ratio, 3:7 to 9:1, morepreferably 4:6 to 9:1, still more preferably 5:5 to 9:1. If the total ofCompound (A) and Compound (B) is less than 30 mass % of the total ofCompound (A), Compound (B) and Compound (C), the flame retardancy may belikely to be reduced, whereas if it exceeds 90 mass %, there may be, forexample, a tendency that productization of the coating agent isdifficult, a tendency that the texture is hardened or powdering occurs,and a tendency that the adhesiveness of the flame-retardant film to theseat material is reduced to fail in obtaining sufficient cloth strength.

According to the aspect b of the present invention, a more advantageouseffect can be obtained in terms of “enhancement of flame retardancy,capability of texture adjustment, prevention of powdering, improvementof adhesiveness, and equalization of coated state”.

According to another aspect c of the present invention, aflame-retardant coating agent for a vehicle seat, containing (A) anitrogen-containing compound, (D) a metal hydroxide, and (C) an aqueousthermoplastic resin may be provided.

According to the aspect c of the present invention, an effect that “thecost is reduced, the thickness and penetration degree of the coatinglayer are easily adjusted, the texture control is easy, and the checkingof processing history is facilitated” can be obtained.

According to another aspect d of the present invention, aflame-retardant coating agent for a vehicle seat, containing (A) anitrogen-containing compound, (B) a phosphorus-based compound, (C) anaqueous thermoplastic resin, and (D) a metal hydroxide may be provided.

According to the aspect d of the present invention, an effect combiningand balancing the effect in the aspect b and the effect in the aspect ccan be obtained.

Effect of the Invention

According to the flame-retardant coating agent for a vehicle seat of thepresent invention, it is possible to provide a flame-retardant vehicleseat material, which contains no halogen and no antimony, and is capableof developing sufficient flame retardancy equal to or greater than thatof APP, and of suppressing the occurrence of water spotting by hotwater.

MODES FOR CARRYING OUT THE INVENTION

Hereinbelow, the flame-retardant coating agent for a vehicle seat andthe process for producing a flame-retardant vehicle seat materialaccording to the present invention will be described in detail.

(A) Nitrogen-Containing Compound

(A) Nitrogen-containing compound (hereinafter, simply referred to as“Compound (A)”), when it is used in combination with (B)phosphorus-based compound (hereinafter, simply referred to as “Compound(B)”) appearing hereinafter, can provide both of the excellent flameretardancy and the suppression of the occurrence of water spotting byhot water, at a higher level than those provided in a case where each ofCompound (A) and Compound (B) is used alone.

Specific examples of Compound (A) may include: melamine compounds,guanamine compounds; triazine compounds; cyanuric acid compounds; andsalts of an acid and at least one kind selected from the groupconsisting of melamine compounds, guanamine compounds and triazinecompounds; etc.

Specific examples of the melamine compound may include: melamine;substituted melamine compounds, e.g., alkylmelamines such as2-methylmelamine, and guanylmelamines; deammoniation condensationproducts of melamine, such as melam, melem, melon and methone; etc.

Specific examples of the guanamine compound may include: guanamine,methylguanamine, acetoguanamine, benzoguanamine, succinoguanamine,3,9-bis[2-(3,5-diamino-2,4,6-triazaphenyflethyl]-2,4,8,10-tetraoxaspiro[5,5]undecane,etc.

Specific examples of the triazine compound may include: 1,2,3-triazine,1,2,4-triazine, 1,3,5-triazine, benzotriazine, and aminogroup-containing triazins wherein 1 to 3 amino groups are substituted ona carbon atom constituting the above compound.

Specific examples of the cyanuric acid compound may include:(iso)cyanuric acid (herein, “(iso)cyanuric acid” represents bothcyanuric acid and isocyanuric acid), ammeline, ammelide, etc. Theisocyanuric acid compound may also be either hydrate or anhydridethereof.

Specific examples of the acid capable of forming a salt with at leastone kind selected from the group consisting of melamine compounds,guanamine compounds and triazine compounds may include:organic acidssuch as (iso)cyanuric acid, formic acid, acetic acid, oxalic acid,malonic acid, lactic acid, citric acid, benzoic acid, isophthalic acidand terephthalic acid; and inorganic acids such as hydrochloric acid,nitric acid, sulfuric acid, pyrosulfuric acid, methanesulfonic acid,ethanesulfonic acid, para-toluenesulfonic acid, dodecylbenzenesulfonicacid, sulfamic acid, phosphoric acid, pyrophosphoric acid,polyphosphoric acid, phosphoric acid, phenylphosphonic acid,alkylphosphonic acid, phosphorous acid, boric acid and tungstic acid.

One of these Compounds (A) may be used alone, and two or more thereofmay also be used in combination, as desired.

Among these Compounds (A), in view of the flame retardancy, it ispreferred to use melamine compounds, triazine compounds, and saltsthereof with (iso)cyanuric acid.

Among the melamine compounds, deammoniation condensation products ofmelamine, such as melam, melem and melon, may be preferred.

Among the triazine compounds, amino group-containing triazine compounds(particularly, amino group-containing 1,3,5-triazine) may be preferred.

Among the salts of melamine compounds or triazine compound with(iso)cyanuric acid, adducts of melamine compounds and (iso)cyanuric acid(salts of melamine compounds and (iso)cyanuric acid) may be preferred.The ratio (molar ratio) of the former to the later may not beparticularly limited but, for example, the ratio of former:latter may bepreferably 3:1 to 1:2, more preferably 2:1 to 1:2. Among these, melaminecyanurate (i.e., salt of melamine and (iso)cyanuric acid), and melemsalts, melam salts, melon salts, etc., corresponding to the melaminesalts may be preferred. The salt of melamine compounds and (iso)cyanuricacid, unreacted melamine compound or (iso)cyanuric acid may also becontained therein.

In the present invention, in view of reducing water spotting, Compound(A) may preferably be water-insoluble. The “water-insoluble” means that,when Compound (A) is powderized (in the case of a solid), and 10 g ofCompound (A) is then put into 100 g of ion-exchanged water at 20° C.,and strongly shaken at 20° C.±0.5° C. for 1 minute, the degree (gram) towhich Compound (A) is dissolved in 100 g of ion-exchanged water is 1.0 gor less. The “dissolves” as used herein means that the resultant mixturegives a transparent solution, or the above mixing can be conducted in anarbitrary ratio, so as to provide a transparent mixture.

Among such Compounds (A), melamine cyanurate may be most preferred.

(B) Phosphorus-Based Compound

In the present invention, (B) a phosphorus-based compound may be used,as desired.

Specific examples of Compound (B) may include the compounds representedby formulae (1) to (5), polyphosphoric acid compounds, and aluminumphosphates.

One of these compounds (B) may be used alone, or two or more thereof maybe used in combination, as desired.

(Compound of Formula (1))

Specific examples of the compound represented by formula (1) mayinclude: triphenyl phosphate (melting point: 50° C.), naphthyl diphenylphosphate (melting point: 61° C.), dinaphthyl phenyl phosphate,trinaphthyl phosphate (melting point: 111° C.), biphenyl diphenylphosphate (liquid state at 20° C.), tricresyl phosphate (liquid state at20° C.), trixylenyl phosphate (liquid state at 20° C.), phenoxyethyldiphenyl phosphate (melting point: 80° C.), ethylhexyl diphenylphosphate (liquid state at 20° C.), tri(isopropylphenyl) phosphate(liquid state at 20° C.), di(phenoxyethyl)phenyl phosphate, phenoxyethyldinaphthyl phosphate, di(phenoxyethyl)naphthyl phosphate, naphthoxyethyldiphenyl phosphate, di(naphthoxyethyl)phenyl phosphate, naphthoxyethyldinaphthyl phosphate, di(naphthoxyethyl)naphthyl phosphate,anilinodiphenyl phosphate (melting point: 130° C.), dianilinophenylphosphate, trianilinophosphate, triphenylphosphine oxide (melting point:157° C.), etc.

One of these compounds may be used alone, or two or more thereof mayalso be used in combination. Among these, in view of the flameretardancy, phenoxyethyl diphenyl phosphate (melting point: 80° C.),anilinodiphenyl phosphate, triphenylphosphine oxide, or trixylenylphosphate (liquid state at 20° C.) may preferably be used.

(Compound of Formula (2))

Specific examples of the compound represented by formula (2) mayinclude: 10-benzyl-9,10-dihydro-9-oxa-10-phosphaphenathrene-10-oxide(melting point: 115° C.),10-(4-methylbenzyl)-9,10-dihydro-9-oxa-10-phsphaphenanthrene-10-oxide,10-phenethyl-9,10-dihydro-9-oxa-10-phsphaphenanthrene-10-oxide,10-(1-naphthylmethyl)-9,10-dihydro-9-oxa-10-phsphaphenanthrene-10-oxide,10-(2-naphthylmethyl)-9,10-dihydro-9-oxa-10-phsphaphenanthrene-10-oxide,butyl[3-(9,10-dihydro-9-oxa-10-phsphaphenanthrene-10-oxid-10-yl)methyl]succinimide,phenyl[3-(9,10-dihydro-9-oxa-10-phsphaphenanthrene-10-oxid-10-yl)methyl]succinimide,benzyl[3-(9,10-dihydro-9-oxa-10-phsphaphenanthrene-10-oxid-10-yl)methyl]succinimide(melting point: 143° C.), etc. One of these compounds may be used alone,or two or more thereof may also be used in combination. Among these, inview of the flame retardancy,10-benzyl-9,10-dihydro-9-oxa-10-phsphaphenanthrene-10-oxide maypreferably be used.

(Compound of Formula (3))

In formula (3), the arylene group represented by R⁹ may have asubstituent, and specific examples of the substituent may include: alkylgroup having a carbon number of 1 to 4, and hydroxy group. Specificexamples of the arylene group may include: phenylene group, biphenylenegroup, methylenebisphenylene group, dimethylmethylenebisphenylene group,and sulfone bisphenylene group.

Specific examples of the compound represented by formula (3) mayinclude: resorcinol di-2,6-xylenyl phosphate (melting point: 95° C.),resorcinol diphenyl phosphate (liquid state at 20° C.),hydroquinonedi-2,6-xylenyl phosphate, 4,4′-biphenoldi-2,6-xylenylphosphate, 4,4′-biphenoldiphenyl phosphate, 4,4′-biphenoldicresylphosphate, biphenol A diphenyl phosphate (liquid state at 20° C.),biphenol A dicresyl phosphate (liquid state at 20° C.), etc. One ofthese compounds may be used alone, or two or more thereof may also beused in combination. Among these, in view of the flame retardancy,resorcinol di-2,6-xylenyl phosphate or resorcinol diphenyl phosphate(liquid state at 20° C.) may preferably be used.

(Compound of Formula (4))

Specific examples of the compound represented by formula (4) mayinclude:5,5-dimethyl-2-(2′-phenylphenoxy)-1,3,2-dioxaphospholinane-2-oxide(melting point: 129° C.),5,5-dimethyl-2-(4′-phenylphenoxy)-1,3,2-dioxaphospholinane-2-oxide,5-butyl-5-ethyl-2-(4′-phenylphenoxy)-1,3,2-dioxaphospholinane-2-oxide,5,5-dimethyl-2-(2′-naphthyloxy)-1,3,2-dioxaphospholinane-2-oxide, etc.One of these compounds may be used alone, or two or more thereof mayalso be used in combination. Among these, in view of the flameretardancy,5,5-dimethyl-2-(2′-phenylphenoxy)-1,3,2-dioxaphospholinane-2-oxide maypreferably be used.

(Compound of Formula (5))

Specific examples of the compound represented by formula (5) mayinclude:5-ethyl-5-[[[methoxy(methyl)phosphinyl]oxy]methyl]-2-methyl-1,3,2-dioxaphospholinane2-oxide (liquid state at 20° C.)

Among the compounds represented by formulae (1) to (5), in view ofreducing water spotting, compounds having a melting point of 95° C. ormore, or a melting point of 20° C. or less may be preferred.

A compound having a melting point of 95° C. or more may impart a hardtexture (or feel) to the flame-retardant seat material, and a compoundhaving a melting point of 20° C. or less may impart a soft texture.Accordingly, the combination of the compound having a melting point of95° C. or more and the compound having a melting point of 20° C. or lessmay also be advantageous in that the texture may arbitrarily beadjusted.

(Polyphosphoric Acid Compound)

The polyphosphoric acid compound may include: polyphosphoric acid,ammonium polyphosphate, polyphosphoric acid amide, polyphosphoric acidcarbamate, sodium tripolyphosphate, potassium polyphosphate, ammoniumpotassium polyphosphate, guanidine polyphosphate, melaminepolyphosphate, guanylurea phosphate, surface-coated ammoniumpolyphosphate, etc.

Among these, in view of the flame retardancy and water spottingreduction, surface-coated ammonium phosphate may be preferred. Amongothers, the surface-coated ammonium polyphosphate may preferably besilane-coated or melamine-coated ammonium polyphosphate. In view of notemitting VOC, silane-coated ammonium polyphosphate may more preferablybe used.

Specific examples of the silane-coated ammonium polyphosphate mayinclude: FRCROS 486 (mfd. by Budenheim), Exflam APP-204 (mfd. byWellchem), APP-102, APP-105 (mfd. by JLS), APP-5 (mfd. by Xi'an ChemicalIndustries), etc.

In the present invention, in view of reducing water spotting, Compound(B) may preferably be water-insoluble. The “water-insoluble” means that,when Compound (B) is powderized (in the case of a solid), and 10 g ofCompound (B) is then put into 100 g of ion-exchanged water at 20° C.,and strongly shaken at 20° C.±0.5° C. for 1 minute, the degree (gram) towhich Compound (B) is dissolved in 100 g of ion-exchanged water is 1.0 gor less. The “dissolves” as used herein means that the resultant mixturegives a transparent solution, or the above mixing can be conducted in anarbitrary ratio, so as to provide a transparent mixture.

Among these compounds (B), in view of the flame retardancy, waterspotting reduction and cost, biphenyl diphenyl phosphate, tricresylphosphate, tri-2,6-xylenyl phosphate,10-benzyl-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, andresorcinol di-2,6-xylenyl phosphate may be more preferred.

(C) Aqueous Thermoplastic Resin

(C) Aqueous thermoplastic resin (hereinafter, simply referred to as“Compound (C)”) is a binder resin to be used for fixing Compound (A) (asdesired, further Compound (B) and/or Compound (D)) to the vehicle seatmaterial. When “Compound (C)” is used in combination with Compound (A)(as desired, further Compound (B) and/or Compound (D)), it may producean effect of imparting good flame retardancy to the vehicle seatmaterial, and of suppressing the occurrence of water spotting by hotwater.

In an embodiment of the present invention containing Compound (A) andCompound (C), in view of the flame retardancy, texture, powdering, andadhesiveness of the flame-retardant film to the seat material, etc., themixing ratio (A):(C) of Compound (A):Compound (C) may preferably be, inmass ratio, 1:9 to 9.5:0.5, more preferably 3:7 to 9:1, still morepreferably 4:6 to 9:1, yet still more preferably 5:5 to 9:1.

In the present invention, the “aqueous thermoplastic resin” refers to athermoplastic resin having a property such that, even when 200 mL of awater-emulsified/dispersed liquid of the thermoplastic resin at aconcentration in water of 40 mass % is put into a 200-mL glass vessel(with a lid) and then the lid is closed, and thereafter the class vesselis left standing still on an ordinary lab bench at 20° C. for 12 hours,the separation or precipitation is not observed in thewater-emulsified/dispersed liquid.

Specific examples of the Compound (C) may include: aqueous acrylicresins, acrylic polyurethane resins, aqueous vinyl acetate resins, andaqueous ethylene-vinyl acetate resins, etc.

One of these Compounds (C) may be used alone, or two or more may also beused in combination.

Among these, Compound (C) may preferably be an aqueous acrylic resin inview of the soft texture and cost; may preferably be an aqueouspolyurethane resin in view of the flame retardancy and hard texture; andmay preferably be an aqueous polyurethane resin; and more preferably bean anionic group-containing polyurethane resin, in view of reduction ofwater spotting.

The combination of an aqueous acrylic resin and an aqueous polyurethaneresin may also be advantageous in that the texture of theflame-retardant seat material may arbitrarily be adjusted.

As the aqueous acrylic resin, a commercially available product may beused. Examples thereof may include: Nikasol Series (mfd. by NipponCarbide Industries Co., Inc.), Polysol Series (mfd. by Showa HighpolymerCo., Ltd.), Saivinol Series (mfd. by Saiden Chemical industry Co.,Ltd.), and Newcoat FH Series (mfd. by Shin-Nakamura Chemical Co., Ltd.).

(Anionic Group-Containing Polyurethane Resin)

As the anionic group-containing polyurethane resin, it is preferred touse an anionic group-containing aqueous polyurethane resin, which hasbeen obtained by a method wherein an isocyanate group-terminatedneutralized prepolymer having an anionic group; the isocyanategroup-terminated neutralized prepolymer having been obtained by reacting(a) an organic polyisocyanate, (b) a polyol, and (c) a compound havingan anionic group and two or more active hydrogen atoms; isemulsified/dispersed in water by self-emulsification so as to cause achain extension reaction by using (d) a polyamine compound having two ormore amino groups and/or imino groups.

The anionic group may include a carboxyl group (—COOH), a carboxylategroup (—COO), a sulfo group (—SO₃H), a sulfonate group (—SO₃), etc.Among others, the anionic group may preferably be a carboxyl groupand/or a carboxylate group, in view of having a tendency that theemulsification/dispersion stability of an anionic group-containingself-emulsifying polyurethane resin is excellent and a tendency that theflame retardancy of a flame-retardant vehicle seat material is littlereduced, and a good effect of reducing water spotting is provided.

The content of the anionic group may preferably be 0.1 to 5.0 mass %,more preferably 0.2 to 4.0 mass %, still more preferably 0.5 to 2.5 mass%. Here, the base for calculating “mass %” is the mass of a resincontaining an anionic group. That is, the “mass %” is calculatedtheoretically from the chemical structural formula and mixing amount ofthe resin.

If the content of the anionic group is less than the lower limit asstated above, the aqueous polyurethane resin may be difficult to beemulsified/dispersed, so as to show a tendency that the stability of thewater-emulsified/dispersed liquid of the thermoplastic resin isdeteriorated and a tendency that the flame retardancy is reduced orwater spotting is worsened. If the content of the anionic group exceedsthe upper limit as stated above, the aqueous polyurethane resin may bedifficult to cause sharp heat-sensitive solidification, so as to show atendency that bleed-through (or strike-through) occurs.

One of these aqueous polyurethane resins may be used alone, or two ormore thereof may also be used in combination, as desired.

<(a) Organic Polyisocyanate>

The (a) organic polyisocyanate which is usable at the time of producingthe aqueous polyurethane resin according to the present invention maynot be particularly limited. For example, diisocyanate compounds,triisocyanate compounds, and modified polyisocyanate compounds such asdimers or trimers of diisocyanate compound, may be used as the (a)organic polyisocyanate.

Specific examples of the diisocyanate compound may include: aliphaticdiisocyanate compounds such as tetramethylene diisocyanate,hexamethylene diisocyanate, dodecamethylene diisocyanate, andtrimethylbexamethylene diisocyanate; alicyclic diisocyanate compoundssuch as isophorone diisocyanate, hydrogenated xylylene diisocyanate,dicyclohexylmethane diisocyanate, norbornane diisocyanate,1,3-bis(isocyanatomethyl)cyclohexane, and3,3′-dimethyl-4,4′-dicyclohexylmethane diisocyanate; and aromaticdiisocyanate compounds such as phenylene diisocyanate, tolylenediisocyanate, diphenylmethane diisocyanate,3,3′-dimethyl-4,4′-biphenylene diisocyanate,3,3′-dichloro-4,4′-biphenylene diisocyanate, naphthalene diisocyanate,tolidine diisocyanate, xylylene diisocyanate, and tetramethylxylylenediisocyanate, etc.

Specific examples of the triisocyanate compound may include:triphenylmethane triisocyanate, dimethyltriphenylmethanetetraisocyanate, and tris(isocyanatophenyl)-thiophosphate, etc.

The modified polyisocyanate compound derived from a diisocyanatecompound may not be particularly limited as long as it has two or moreisocyanate groups. Specific examples thereof may include:polyisocyanates having a buiret structure, an isocyanurate structure, aurethane structure, a uretdione structure, an allophanate structure, atrimer structure, etc.; trimethylolpropane adducts of aliphaticisocyanate, and polymeric MDI (MDI=diphenylmethane diisocyanate), etc.

One of these polyisocyanate compounds may be used alone, or two or morethereof may also be used in combination, as desired.

Among these polyisocyanate compounds, an aliphatic polyisocyanate and analicyclic polyisocyanate may have a tendency of providing anon-yellowing flame-retardant seat material, and therefore, maypreferably be used.

<(b) Polyol>

The (b) polyol usable at the time of producing the aqueous polyurethaneresin according to the present invention may not be particularly limitedas long as it has two or more hydroxyl groups, and polyester polyols,polycarbonate polyols, polyether polyols, dimer diols, etc., may be usedas the (b) polyol.

(Polyester Polyol)

Specific examples of the polyester polyol may include: polyethyleneadipate diols, polybutylene adipate diols, polyethylene-butylene adipatediols, polyhexamethylene isophthalate adipate diols, polyhexamethylenesuccinate diols, polybutylene succinate diols, polyethylene sebacatediols, polybutylene sebacate diols, poly-ω-caprolactone diols,poly(3-methyl-1,5-pentylene)adipate diols, polycondensates of1,6-hexanediol and dimer acid, copolycondensates of 1,6-hexanediol,adipic acid and dimer acids, polycondensates of nonane diol and dimesacid, and copolycondensates of ethylene glycol, adipic acid and dimeracid, etc.

(Polycarbonate Polyol)

Specific examples of the polycarbonate polyol may include: polycarbonatepolyols which have been obtained by the reaction of a glycol such as1,4-butanediol, 1,6-hexanediol and diethylene glycol, with diphenylcarbonate, phosgene, etc. Specific examples of the polycarbonate polyolmay include: polytetramethylene carbonate diols, polyhexamethylenecarbonate diols, 3-methyl-1,5-pentanediol carbonate diols,poly-1,4-cyclohexanedimethylene carbonate diols, and 1,6-hexanediolpolycarbonate diols, etc.

(Polyether Polyol)

Specific examples of the polyether polyol may include: polymers whichhave been obtained by the addition polymerization, in an ordinarymanner, of a compound having at least two active hydrogen atoms, such asethylene glycol, diethylene glycol, triethylene glycol, propyleneglycol, trimethylene glycol, 1,3-butanediol, 1,4-butanediol,1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, glycerin,trimethylolethane, trimethylolpropane, sorbitol, sucrose, bisphenol A,bisphenol S, hydrogenated bisphenol A, aconitic acid, trimellitic acid,hemimellitic acid, phosphoric acid, ethylenediamine, diethylenetriamine,triisopropanolamine, pyrogallol, dihydroxybenzoic acid, hydroxyphthalicacid, 1,2,3-propanetrithiol, monoethanolamine, diethanolamine, andtriethanolamine; with one kind of monomer or two or more kinds ofmonomers, such as ethylene oxide, propylene oxide, butylene oxide,styrene oxide, trimethylene oxide, tetramethylene oxide,epichlorohydrin, tetrahydrofuran, and cyclohexylene. In this case, themethod for addition polymerization may be any of homopolymerization,block copolymerization, and random copolymerization, etc.

(Dimer Diol)

Specific examples of the dimer diol may include compounds containing, asthe main component, a diol which has been obtained by reducing apolymerized fatty acid. The polymerized fatty acid may include compoundswhich have been obtained by Diels-Alder type bimolecular polymerizationreaction of: unsaturated fatty acids having a carbon number of 18, suchas oleic acid and linoleic acid; drying oil fatty acids, semidrying oilfatty acids, and lower monoalcohol esters of these fatty acids.

One of these polyols may be used alone, or two or more thereof may alsobe used in combination, as desired. The weight-average molecular weightof the polyol may preferably be 500 to 5,000, more preferably 1,000 to3,000. The “weight-average molecular weight” is determined bycalculation based on the analysis value=OHV (OH value) available fromthe manufacturer of the raw material.

Among these polyols, from the standpoint that the flame-retardant seatmaterial little suffers from a reduction in the strength due tohydrolysis with the elapse of time, at least one kind selected from thegroup consisting of: polycarbonate polyols and polyether polyols may bepreferred.

<(c) Compound Having Anionic Group and Two or More Active Hydrogens>

The (c) compound having an anionic group and two or more active hydrogenatoms, which may be used at the time of producing the aqueouspolyurethane resin according to the present invention, may not beparticularly limited. Specific examples thereof may include: carboxylgroup-containing low molecular diols such as 2,2-dimethylolpropionicacid and 2,2-dimethylolbutanoic acid, sulfone group-containing lowmolecular diols such as 2-sulfo-1,3-propanediol and2-sulfo-1,4-butanediol; and ammonium salts, organic amine salts (such asthose of trimethylamine, triethylamine, tri-n-propylamine,tributylamine, triethanolamine, N,N-dimethyldiethanolamine andN,N-diethylethanolamine, alkali metal salts (such as those of sodium andpotassium) of these carboxyl group-containing low molecular diols orsulfone group-containing low molecular diols as stated above. One ofthese compounds may be used alone, or two or more thereof may also beused in combination, as desired.

<(d) Polyamine Compound Having Two or More Amino Groups and/or IminoGroups>

The (d) polyamine compound having two or more amino groups and/or iminogroups, which may be used at the time of producing the aqueouspolyurethane resin according to the present invention, may not beparticularly limited. Specific examples thereof may include: diaminessuch as ethylenediamine, propylenediamine, tetramethylenediamine,hexamethylenediamine, diaminocyclohexylmethane, piperazine, hydrazine,2-methylpiperazine, isophoronediamine, norbornanediamine,diaminodiphenylmethane, tolylenediamine, and xylylenediamine; polyaminessuch as diethylenetriamine, triethylenetetramine,tetraethylenepentamine, iminobispropylamine, andtris(2-aminoethyl)amine; amidoamines derived from di-primary-amine andmonocarboxylic acid; water-soluble amine derivatives such as monoketiminof di-primary-amine; and hydrazine derivatives such as oxalic aciddihydrazide, malonic acid dihydrazide, succinic acid dihydrazide,glutaric acid dihydrazide, adipic acid dihydrazide, sebacic aciddihydrazide, maleic acid dihydrazide, fumaric acid dihydrazide, itaconicacid dihydrazide, 1,1′-ethylene dihydrazine, 1,1′-trimethylenedihydrazine, and 1,1′-(1,4-butylene)dihydrazine, etc. One of thesepolyamine compounds having two or more amino groups and/or imino groupsmay be used alone, or two or more thereof may also be used incombination, as desired.

(Anionic Group-Containing Polyurethane Resin)

The anionic group-containing polyurethane resin may be obtained as anemulsified/dispersed liquid of the polyurethane resin byemulsifying/dispersing an isocyanate group-terminated neutralizedprepolymer having an anionic group in water by self-emulsification so asto cause a chain extension reaction.

The isocyanate group-terminated neutralized prepolymer having an anionicgroup may be an isocyanate group-terminated neutralized prepolymerhaving a group resulting from the neutralization of an anionic grouporiginating in the (c) compound having an anionic group and two or moreactive hydrogen atoms, and may be obtained by reacting the (a) organicpolyisocyanate, the (b) polyol, and the (c) compound having an anionicgroup and two or more active hydrogen atoms.

Specific method for obtaining the isocyanate group-terminatedneutralized prepolymer having an anionic group may not be particularlylimited, and the compound may be produced, for example, by aconventionally known one-stage (so-called one-shot), or multi-stageisocyanate polyaddition reaction method. At this time, the reactiontemperature may preferably be 40 to 150° C.

(Low Molecular-Weight Chain Extender)

At the time of reaction as stated above, a low molecular-weight chainextender having two or more active hydrogen atoms may be used, asdesired. The low molecular-weight chain extender may preferably be achain extender having a molecular weight of 400 or less, particularly300 or less. Specific examples of the low molecular chain extender mayinclude: low molecular-weight polyhydric alcohols such as ethyleneglycol, propylene glycol, neopentyl glycol, 1,4-butanediol,1,6-hexanediol, trimethylolpropane, pentaerythritol, and sorbitol; andlow molecular-weight polyamines such as ethylenediamine,propylenediamine, hexamethylenediamine, diaminocyclohexylmethane,piperazine, 2-methylpiperazine, isophoronediamine, diethylenetriamine,and triethylenetetramine. One of these low molecular-weight chainextenders may be used alone, or two or more thereof may also be used incombination.

(Neutralization of Anionic Group)

The neutralization of an anionic group originating in the (c) compoundhaving an anionic group and two or more active hydrogen atoms may beeffected simultaneously with the preparation of an isocyanategroup-terminated prepolyrner, or before or after such a preparation. Theneutralization may be performed by appropriately using a known method,and the compound used for the neutralization may not be particularlylimited. Specific examples thereof may include: amines such astrimethylamine, triethylamine, tri-n-propylamine, tributylamine,N-methyl-diethanolamine, N,N-dimethylmonoethanolamine,N,N-diethylmonoethanolamine, and triethanolamine; potassium hydroxide;sodium hydroxide; sodium carbonate; ammonia, etc. Among these, tertiaryamines such as trimethylamine, triethylamine, tri-n-propylamine andtributylamine may particularly be preferred.

The method for emulsifying/dispersing an isocyanate group-terminatedneutralized prepolymer having an anionic group in water may not beparticularly limited. Specific examples thereof may include: a methodusing an emulsification/dispersion device such as homomixer,homogenizer, and disper. At the time of emulsifying/dispersing anisocyanate group-terminated neutralized prepolymer having an anionicgroup in water, the neutralized prepolymer may preferably beemulsified/dispersed in water by self-emulsification at a temperature of5 to 40° C. by not particularly using an emulsifier, so as to suppressthe reaction of an isocyanate group with water, as completely aspossible. In the case of using an emulsifier, the performance in termsof the flame retardancy and water spotting may tend to be reduced.

Further, at the time of emulsification/dispersion, a reactioncontrolling agent such as phosphoric acid, sodium dihydrogenphosphate,disodium hydrogenphosphate, para-toluenesulfonic acid, adipic acid, andbenzoyl chloride may be added, as desired.

The chain extension reaction of the isocyanate group-terminatedneutralized prepolymer having an anionic group may be performed byadding the (d) polyamine compound having two or more amino groups and/orimino groups to the isocyanate group-terminated neutralized prepolymerhaving an anionic group, or by adding the isocyanate group-terminatedneutralized prepolymer having an anionic group to the (d) polyaminecompound having two or more amino groups and/or imino groups. Such achain extension reaction may preferably be performed at a reactiontemperature of 20 to 40° C. and may usually be completed in 30 to 120minutes.

In the process for producing the polyurethane resin having an anionicgroup, the emulsification/dispersion and the chain extension reactionmay be effected at the same time, or the isocyanate group-terminatedneutralized prepolymer having an anionic group may beemulsified/dispersed and then chain-extended, or may be chain-extendedand then emulsified/dispersed.

Such an aqueous polyurethane resin may usually be obtained as anemulsified dispersion of the resin and distributed in the market. Theaqueous polyurethane resin according to the present invention maypreferably be used in a state of being thus emulsified/dispersed inwater, and the concentration thereof may not be particularly limited butmay preferably be 15 to 60 mass %, because of a tendency that thecoating agent according to the present invention may be easily obtainedin a uniform state, or in consideration of the performance of theflame-retardant seat material.

Compound (D):

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, in view of cost and enhancement of flame retardancyby cooling at the time of burning the flame-retardant seat material, (D)a metal hydroxide (hereinafter, simply referred to as Compound (D)) maypreferably be used in combination. The Compound (D) may preferably be atleast one kind selected from the group consisting of aluminum hydroxide,magnesium hydroxide, and calcium hydroxide. As Compound (D), two or morekinds of compounds may be combined, as desired. Among these, in thelight of flame retardancy and supply, aluminum hydroxide and magnesiumhydroxide may be preferred, and aluminum hydroxide may be morepreferred. In view of the flame retardancy and whitening or powdering ofthe coating surface, the average particle size of Compound (D) maypreferably be 20 μm or less, more preferably 10 μm or less. In addition,in view of flame retardancy, the content of SiO₂ in aluminum hydroxidemay preferably be 0.02% or less.

In an embodiment of the present invention wherein Compound (D) iscontained in addition to Compound (A) and Compound (C), in view of theflame retardancy, texture, powdering, adhesiveness of theflame-retardant film to the seat material, etc., the ratio (A):(D) ofCompound (A) to Compound (D) may preferably be, in mass ratio, 1:0.1 to10, more preferably 1:0.1 to 7, still more preferably 1:01 to 5. Inaddition, in view of, e.g., flame retardancy, texture, powdering,adhesiveness of the flame-retardant film to the seat material, themixing ratio {(A)+(D)}:(C) of {Compound (A)+Compound (D)}:Compound (C)may preferably be, in mass ratio, 3:7 to 9:1, more preferably 4:6 to9:1, still more preferably 5:5 to 9:1.

The mixing amount of Compound (D) may not be particularly limited butmay preferably be less than 80 mass %, more preferably less than 70 mass%, with respect to the total of Compound (A), Compound (B) and Compound(D).

If the mixing amount of Compound (D) is 80 mass % more with respect tothe total of Compound (A), Compound (B) and Compound (D), the flameretardancy, the adhesiveness of the flame-retardant film to the seatmaterial, etc., may tend to be reduced.

(Preferable Quantitative Ratio Among Compounds (A) to (D))

In the embodiment of the flame-retardant coating agent for a vehicleseat according to the present invention containing Compound (B) and/orCompound (D), (A):{(B)+(D)} may preferably be, in mass ratio, 1:0.1 to15, more preferably 1:0.1 to 10, still more preferably 1:0.1 to 7, yetstill more preferably 1:0.1 to 5. Out of this range, it may tend to bedifficult to achieve a good balance of performances.

In this embodiment, the mixing ratio {(A)+(B)+(D)}:(C) of the total ofCompound (A), Compound (B) and Compound (D) to Compound (C) maypreferably be, in mass ratio, 1:9 to 9.5:0.5, more preferably 3:7 to9:1, still more preferably 4:6 to 9:1, yet still more preferably 5:5 to9:1. If the total of Compound (A), Compound (B) and Compound (D) is lessthan 30 mass % in terms of the ratio to the total of the Compound (A),Compound (B), Compound (C) and Compound (D) (i.e.,{(A)+(B)+(D)}/{(A)+(B)+(C)+(D)}<0.30), the flame retardancy may tend tobe reduced. On the other hand, if this ratio{(A)+(B)+(D)}/{(A)+(B)+(C)+(D)} is >0.9, there may be, for example, atendency that productization of the coating agent is difficult, atendency that the texture is hardened or powdering occurs, and atendency that the adhesiveness of the flame-retardant film to the seatmaterial is reduced to fail in obtaining sufficient cloth strength.

(Solvent)

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, at the time of mixing of Compound (A) and Compound(C) (as desired, further Compound (B) and/or Compound (D)), water maypreferably be used as the solvent. As the water, ion-exchanged water ordistilled water may preferably be used.

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, an organic solvent may also be used in combination asthe solvent. The organic solvent may include glycols such as ethyleneglycol, diethylene glycol, butyl glycol, and butyl diglycol; alcoholssuch as methanol, ethanol, and isopropanol; etc. In view of waterspotting, cost, hazardous material, fastness, viscosity andbleed-through, the content of the organic solvent may preferably be 10mass % or less, more preferably 5 mass % or less, most preferably 0 mass% , with respect to water.

(pH Adjusting Agent)

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, for example, sodium hydroxide, potassium hydroxide,sodium carbonate, sodium bicarbonate, ammonia, hydrochloric acid,sulfuric acid, nitric acid, phosphoric acid, or acetic acid, etc., maybe used as the pH adjusting agent.

(Thickener)

In the present invention, in view of adjusting the viscosity andstickiness of the flame-retardant coating agent for a vehicle seataccording to the present invention and adjusting the coatability for avehicle seat material, a thickener may preferably be used.

Specific examples of the thickener may include a natural water-solubleorganic polymer such as gum arabic, tragacanth gum, guar gum, locustbean gum, sodium alginate, carrageenan, xanthan gum, and pullulan; asemisynthetic water-soluble organic polymer such as methyl cellulose,ethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, andcarboxymethyl cellulose; a synthetic water-soluble organic polymer suchas polyvinyl alcohol, urethane resin, and alkali thickening type acrylicresin; etc.

One of these thickeners may be used alone, or two or more thereof mayalso be used in combination, as desired.

Among the thickeners as stated above, in view of coatability, xanthangum, hydroxyethyl cellulose, polyvinyl alcohol, urethane resin, andalkali thickening type acrylic resin may preferably be used.

The urethane resin may include a polyether polyol-based urethanepolymer. As the polyether polyol-based urethane polymer, a commerciallyavailable product may be used. Specific examples thereof may include:Adekanol UH-420, Adekanol UH-450, Adekanol UH-540, Adekanol UH-752 (allmfd. by ADEKA Corporation), SN Thickener 601, SN Thickener 612, SNThickener 621N, SN Thickener 623N (all mfd. by San Nopco Limited),Rheolate 244, Rheolate 278, Rheolate 300 (all mfd. by Elementis Japan),and DK Thickener SCT-275 (mfd. by DES Co. Ltd.), etc.

(Alkali Thickening Type Acrylic Resin)

The alkali thickening type acrylic resin may preferably be apolymerization product of a monomer composition containing at least onemonomer selected from the group consisting of a carboxylgroup-containing monomer and a (meth)acrylic acid ester monomer.

Among such alkali thickening type acrylic resins, the alkali thickeningtype acrylic resin may preferably be a resin obtained byemulsion-polymerizing a monomer composition containing at least onemonomer selected from the group consisting of a carboxylgroup-containing monomer and a (meth)acrylic acid ester monomer, in thepresence of a polymerization initiator, a surfactant, a chain transferagent, a crosslinking agent, etc., as desired.

Specific examples of the carboxyl group-containing monomer as aconstituent of the alkali thickening type acrylic resin may include: amonocarboxylic acid-based monomer such as (meth)acrylic acid, crotonicacid, cinnamic acid, and atropic acid; a dicarboxylic acid-based monomersuch as itaconic acid, maleic acid, fumaric acid, citraconic acid, andmesaconic acid, and an acid anhydride thereof; and a dicarboxylic acidmonoalkyl ester-based monomer. Among these, acrylic acid and methacrylicacid may be preferred, and methacrylic acid may be more preferred.

Specific examples of the (meth)acrylic acid ester monomer may include: a(meth)acrylic acid alkyl ester monomer having an alkyl group with acarbon number of 1 to 22, which may have a phenyl group, and a(meth)acrylic acid alkyl ester monomer having an alkyl group with acarbon number of 1 to 4 may be preferred.

In the alkali thickening type acrylic resin according to the presentinvention, other than at least one monomer selected from the groupconsisting of a carboxyl group-containing monomer and a (meth)acrylicacid ester monomer, a monomer copolymerizable therewith may be used as aconstituent. Such a copolymerizable monomer may include: a vinylcarboxylate-based monomer, a styrene-based monomer, a hydroxylgroup-containing monomer, an amide group-containing monomer, and a cyanogroup-containing monomer.

Specific examples of the vinyl carboxylate-based monomer may include: avinyl carboxylate having an alkyl group with a carbon number of 1 to 21or a phenyl group and may preferably be vinyl acetate or vinylpropionate.

Specific examples of the styrene-based monomer may include styrene,methylstyrene, ethylstyrene, isopropyistyrene, and tert-butylstyrene,with styrene being preferred.

Specific examples of the hydroxyl group-containing monomer may include ahydroxyalkyl (meth)acrylate having a carbon number of 2 to 4, apolyoxyalkylene mono(meth)acrylate having a carbon number of 2 to 8,glycerin mono(meth)acrylate, pentaerythritol mono(meth)acrylate,(meth)allyl alcohol, glycerin mono(meth)allyl ether, etc.

Specific examples of the amide group-containing monomer may include(meth)acrylamide, an N-alkyl (meth)acrylamide having a carbon number of1 to 4, an N-hydroxyalkyl (meth)acrylamide having a carbon number of 1to 3, an N-alkoxymethyl (meth)acrylamide having a carbon number of 1 to4, diacetone (meth)acrylamide, maleic acid amide, a maleic acid imide,etc. The cyano group-containing monomer may include (meth)acrylonitrile,α-chloroacrylonitrile, α-ethylacrylonitrile, etc. In the as statedabove, the (meth)acryl may mean both acryl and methacryl.

(Polymerization Initiator)

Specific examples of the polymerization initiator usable at the time ofproducing an alkali thickening type acrylic resin may include: a radicaldonator such as hydrogen peroxide, ammonium persulfate, potassiumpersulfate, a redox-type initiator (hydrogen peroxide-ferrous chloride,ammonium persulfate-acidic sodium sulfite, ascorbic acid (salt),rongalite, etc.), 1,1-di-tert-butylperoxy-2-methylcyclohexane,2,2-bis(4,4-di-tert-butylperoxycyclohexyl)propane, and a water-solubleazo-based initiator. In addition, a radical may be generated byphotopolyrnerization with an ultraviolet ray, an electron beam, aradiation beam, etc., and in this case, a photosensitizer, etc., may beused.

(Surfactant)

As the surfactant usable at the time of producing the alkali thickeningtype acrylic resin, at least one of the later-described known nonionicsurfactant and anionic surfactant may be used.

(Chain Transfer Agent)

As the chain transfer agent which is usable at the time of producing thealkali thickening type acrylic resin, those which may be used inemulsion polymerization. Specific examples thereof may include:mercaptans such as n-hexylmercaptan, n-octylmercaptan,n-dodecylmercaptan, t-dodecylmercaptan and n-stearylmercaptan,tetraethylthiuranium sulfide, pentaphenylethane, terpinolene, andα-methylstyrene dimer. These chain transfer agents may be usedindividually or in combination of two or more thereof, as desired. Thecrosslinking agent usable at the time of producing the alkali thickeningtype acrylic resin may not be particularly limited, as long as it is acompound having two or more radical-polymerizable double bonds. Specificexamples of the crosslinking agent may include: ethylene glycoldi(meth)acrylate, propylene glycol di(meth)acrylate, glycerindi(meth)acrylate, glycerin tri(meth)acrylate, diethylene glycoldi(meth)acrylate, diallyl phthalate, diallyl maleate, diallyl fumarate,allyl (meth)acrylate, N,N′-methylene bis(meth)acrylate, anddivinylbenzene. Such an agent may be used, as desired.

In addition, a pH buffering agent, a chelating agent, etc., may be usedat the time of polymerization. Specific examples of the pH bufferingagent may include sodium hydrogencarbonate, sodium carbonate, sodiumdihydrogenphosphate, sodium phosphate, sodium acetate, and potassiumacetate. Specific examples of the chelating agent may include sodiumethylenediaminetetraacetate and sodium nitrilotriacetate.

As to the alkali thickening type acrylic resin, a commercially availableproduct may be used, and examples thereof may include the followings:

Nikasol VT-253A (mfd. by Nippon Carbide Industries Co., Inc.), ARONA-20P, ARON A-7150, ARON A-7070, ARON B-300, ARON B-300K, ARON B-500,ARON A-20L (all mfd. by Toagosei Co., Ltd.), JURYMER AC-10LHP, JURYMER.AC-10SHP, RHEOGIC 250H, RHEOGIC 835H, JUNLON PW-110, JUNLON PW-150 (allmfd. by Nihon Junyaku Co., Ltd.), PRIMAL ASE-60, PRIMAL TT-615, PRIMALRM-5 (all mfd. by Rohm and Haas Company), SN Thickener A-818, SNThickener A-850, SN Thickener 902 (all mfd. by San Nopco Limited),Rheolate 430 (mfd. by Elementis Japan), OSTECKER V-500 (mfd. by NiccaChemical Co., Ltd.), Vanasol K (mfd. by Shin-Nakamura Chemical Co.,Ltd.), and VONCOAT HV-E (mfd. by DIC Corporation), etc.

The amount of the thickener used may preferably be 0.1 to 2.0 mass %,more preferably 0.3 to 1.5 mass %, with respect to the flame-retardantcoating agent for a vehicle seat.

If the amount used is less than 0.1 mass %, there may be a tendency thatstorage stability of the flame-retardant coating agent for a vehicleseal is reduced, and a tendency that uniform processing is difficult dueto an excessive coating amount or bleed-through. If the amount usedexceeds 2.0 mass %, there may be a tendency that the extensibility atthe time of coating gets poor, making uniform processing difficult, or atendency that the effect of reducing water spotting is deteriorated.

In the flame-retardant coating agent for a vehicle seal of the presentinvention, as long as the effect of the present invention is notimpaired, a nitrogen-containing compound, a phosphorus-based compound, athickener, a thermoplastic resin, a deodorant, a foaming agent, etc.,other than those used in the present invention, may be blended.

It may also be possible to use a wax component in combination, as longas the effect of the present invention is not impaired. By using a waxcomponent in combination, smoothness may be imparted to the cloth ofsewing needle and the net-weaving thread, and the sewability and groundthread breakage may be improved. In addition, a water-repellent effectmay be obtained, and the effect of preventing water spotting may tend tobe enhanced. The mixing amount of the wax component may preferably be0.1 to 3.0 mass % with respect to the flame-retardant coating agent fora vehicle seat.

In the present invention, when a polyurethane resin having a carboxylgroup or a carboxylate group is used as Compound (C), as long as theeffect of the present invention is not impaired, a crosslinking agentcapable of reacting with the carboxyl group or carboxylate group may befurther added for the purpose of imparting processing suitability to theobtained flame-retardant vehicle seat material. Such a crosslinkingagent may include: oxazoline-based crosslinking agents, epoxy-basedcrosslinking agents, isocyanate-based crosslinking agents,carbodiimide-based crosslinking agents, azilidine-based crosslinkingagents, block isocyanate-based crosslinking agents, water-dispersedisocyanate-based crosslinking agents, melamine-based crosslinkingagents, etc.

One of these crosslinking agents may be used alone, or two or morethereof may also be used in combination, as desired. Among thesecrosslinking agents, in view of strength and fastness, thecarbodiimide-based crosslinking agent may be preferred. The mixingamount of the crosslinking agent may preferably be 0.5 to 10 mass % withrespect to the aqueous polyurethane resin.

The method for obtaining the flame-retardant coating agent for a vehicleseat according to the present invention may not be particularly limited,and a known method may appropriately be used. The order of or the methodfor blending respective components of (A) and (C) (as desired, furtherCompound (B) and/or Compound (D)) may appropriately be changed, butusually, there may be used a method where a water-emulsified/dispersedliquid containing Compound (A) and Compound (C) (as desired, Compound(B) and/or Compound (D)) is blended, stirred and mixed and theviscosity, pH, solid content, etc. are adjusted with awater-emulsified/dispersed liquid containing an alkali thickening typeacrylic resin, a pH adjusting agent, and a solvent to obtain aflame-retardant coating agent.

(Method for Mixing Compounds (A) and (C))

As to the method for stirring and mixing the mixture of the Compounds(A) and (C) (as desired, further Compound (B) and/or Compound (D)), aconventionally known stirring device or emulsification/dispersion devicemay be used. The conventionally known stirring device oremulsification/dispersion device may not be particularly limited.Specific examples thereof may include a stirring device or anemulsification/dispersion device, such as propeller, kneader, roller,colloid mill, bead mill, Milder, homogenizer, ultrasonic homogenizer,homomixer, homodisper, nanomizer, Ultimizer, and Starburst. Of thesedevices, one kind may be used, or two or more kinds may also be used incombination.

As Compound (A), Compound (B) and Compound (D), awater-emulsified/dispersed liquid thereof may also be used.

As to the method for emulsifying/dispersing Compound (A), Compound (B)and Compound (D), a conventionally known stirring device oremulsification/dispersion device similar to the above may be used.

A surfactant may be used at the time of emulsification/dispersion ofCompound (A), Compound (B) and Compound (D). By using a surfactant,Compound (A), Compound (B) and Compound (D) may be stablymicroparticulated and emulsified/dispersed, powdering on the coatingsurface may be prevented, mixing with a water-emulsified/dispersedliquid containing Compound (C) may be facilitated, and a flame-retardantcoating agent may be easily produced.

Such a surfactant may not be particularly limited, and at least one kindof known nonionic surfactant, anionic surfactant and amphotericsurfactant may be used.

Specific examples of the nonionic surfactant may include: alkylene oxideadducts of linear or branched alcohols or alkenols having a carbonnumber of 8 to 24, alkylene oxide adducts of polycyclic phenols,alkylene oxide adducts of a linear or branched aliphatic amine having acarbon number of 8 to 44, alkylene oxide adducts of a linear or branchedfatty acid amide having a carbon number of 8 to 44, alkylene oxideadducts of a linear or branched fatty acid having a carbon number of 8to 24, a reaction product of a polyhydric alcohol and a linear orbranched fatty acid having a carbon number of 8 to 24 with an alkyleneoxide, and alkylene oxide adducts of oils and fats. One of thesenonionic surfactants may be used alone, or two or more thereof may alsobe used in combination, as desired.

Specific examples of the anionic surfactant may include: anionicsurfactants of a type that is sulfuric acid ester salts, phosphoric acidester salts, carboxylic acid salts or sulfosuccinic acids of thenonionic surfactant as stated above, sulfonic acid ester salts orphosphoric acid ester salts of a higher alcohol, sulfonation products ofoils and fats, alkylbenzenesulfonates, alkylnaphthalenesulfonates, andnaphthalenesulfonate formalin condensates. One of these anionicsurfactants may be used alone, or two or more thereof may also be usedin combination, as desired.

Specific examples of the amphoteric surfactant may includealkylbetaine-type surfactants, amine oxide-type surfactants,glycine-type surfactants, etc. One of these amphoteric surfactants maybe used alone, or two or more thereof may also be used in combination,as desired. Among these, in view of being thermally decomposed and lesslikely to remain on the coating surface and therefore, not reducing theperformance in terms of water spotting, an amine oxide-type surfactantmay be preferred.

Above all, in view of emulsification dispersibility and stability, thesurfactant may preferably be at least one kind selected from the groupconsisting of: alkylene oxide adducts of linear or branched alcoholshaving a carbon number of 8 to 24, alkylene oxide adducts of polycyclicphenols, and anionized products thereof.

The polycyclic phenols may preferably be (3 to 8 mol) styrene adducts,(3 to 8 mol) α-methylstyrene adducts, or a (3 to 8 mol) benzyl chlorideadducts, of phenol, 4-cumylphenol, 4-phenylphenol, or 2-naphthol.

The alkylene oxide may preferably be an ethylene oxide. The added molarnumber may preferably be 10 to 50 mol, more preferably 15 to 40 mol,still more preferably 18 to 35 mol.

(Amount of Surfactant)

The amount of the surfactant in the flame-retardant coating agent for avehicle seat according to the present invention may preferably be 0.1 to3 mass parts per 100 mass parts of the total of Compound (A), Compound(B), Compound (C) and Compound (D). If the amount is less than 0.1 massparts, there may be a tendency that the product stability of theflame-retardant coating agent for a vehicle seat is reduced, or atendency that the flame retardancy of the flame-retardant seat materialis reduced. If the amount exceeds 3 mass parts, the flame-retardant seatmaterial may tend to be reduced in the water spotting preventing effect,fastness, and flame retardancy.

The flame-retardant coating agent for a vehicle seat according to thepresent invention may preferably have an average particle size d(50) of0.5 to 30 μm and a maximum particle size d(max) of 200 μm or less, morepreferably an average particle size d(50) of 0.5 to 20 μm and a maximumparticle size d(max) of 100 μm or less.

If the average particle d(50) exceeds 30 μm or the maximum particle sized(max) exceeds 200 μm, there may be a tendency that the productstability of the flame-retardant coating agent for a vehicle seat isreduced, a tendency that the flame retardancy of the flame-retardantseat material is reduced, or a tendency that the component (A)(depending on the case, further the component (B) and/or the component(D)) is powdered on the surface of the flame-retardant vehicle seatmaterial to degrade the appearance.

If the average particle size d(50) is less than 0.5 μm, a lot of timeand cost may be required to reduce the particle size, leading to anindustrially undesirable tendency.

(Method for Measuring Particle Diameter)

The particle size may be determined by measuring the cumulative volumeparticle size distribution by means of a laser diffraction/scatteringparticle size distribution measuring apparatus and defining the particlesize at a cumulative volume of 50% (median particle size) as the averageparticle size d(50) and the particle size at a cumulative volume of 100%(maximum particle size) as the maximum particle size d(max). Here, asthe particle size distribution meter, “HORIBA Laser DiffractionScattering Particle Size Distribution Measuring Apparatus LA-920” may beused.

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, the pH may preferably be adjusted to a range of 6.0to 10.0, more preferably 7.0 to 9.0 If the pH is less than 6.0, theremay be a tendency toward reduction in the viscosity of theflame-retardant coating agent for a vehicle seat, reduction in theproduct stability, an excessive coating amount of the flame-retardantcoating agent for a vehicle seal with respect to the vehicle seatmaterial, and back-bleeding. If it exceeds 10.0, the uniform coatabilitymay tend to be reduced.

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, the total of Compound (A), Compound (B), Compound (C)and Compound (D) may preferably be 20 to 60 mass %. If the total is lessthan 20 mass %, the coating amount with respect to the vehicle seatmaterial may be insufficient, leading to a tendency that the flameretardancy is reduced or a tendency that the drying requires a longtime. If the total exceeds 60%, the coating amount may become excessivewith little likelihood of further enhancing the flame retardancy andmoreover, various fastnesses may tend to be reduced.

(Viscosity of Flame-Retardant Coating Agent for Vehicle Seat)

The viscosity of the flame-retardant coating agent for a vehicle seataccording to the present invention may preferably be 3,000 to 30,000mPa·s, still more preferably 8,000 to 20,000 mPa·s. If the viscosity isless than 3,000 mPa·s, back-bleeding may tend to be caused, and if theviscosity exceeds 30,000 mPa·s, coating thinning may tend to be caused.

In the case of foam-coating a vehicle seat material with theflame-retardant coating agent for a vehicle seat according to thepresent invention, the viscosity of the flame-retardant coating agentfor a vehicle seat may more preferably be 500 to 10,000 mPa·s. If theviscosity is less than 500 mPa·s, the product stability of theflame-retardant coating agent for a vehicle seat may tend to bedeficient, and if the viscosity exceeds 10,000 mPa·s, there may be atendency that the foaming is poor and good foam-coating may not beconducted.

In the case of performing foam-coating, a foaming agent such asN,N-dimethyldodecylamine oxide or sodium dodecyldiphenyletherdisulfonatemay appropriately be used in combination.

The viscosity (unit: mPa·s) of the flame-retardant coating agent for avehicle seat according to the present invention may be a value obtainedby putting 200 ml of the flame-retardant coating agent for a vehicleseat in a vial with an inner diameter of 50 mm and measuring theviscosity by means of a B-type viscometer (high viscosity type, TokimecInc., BH-type viscometer, Rotor No. 5, 20 rpm, measurement temperature:20° C.)

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, not only the viscosity but also the stickiness may beset to a specific range, whereby good coatability may be obtained. Thestickiness may be determined by measuring the PVI value.

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, the PVI value may preferably be 0.1 to 0.35, morepreferably 0.15 to 0.30, still more preferably 0.15 to 0.25. If the PVIvalue is less than 0.10, there may be a tendency toward coating thinningor incapability of giving a sufficient coating amount, and if it exceeds0.35, an excessive coating amount or back-bleeding may tend to becaused.

The PVI value refers to a printing viscosity index and be a valuecalculated by the following formula by measuring the flame-retardantcoating agent for a vehicle seat under the viscosity measurementconditions as stated above at a rotational speed of 20 rpm and at 2 rpm.

PVI Value=(measured value at rotational speed of 20 rpm)÷(measured valueat rotational speed of 2 rpm)

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, in view of reducing water spotting, the nonvolatilematter of the flame-retardant coating agent for a vehicle seat accordingto the present invention, which may be obtained by heating theflame-retardant coating agent for a vehicle seat according to thepresent invention at 105° C. for 3 hours, may preferably bewater-insoluble. The water-insoluble refers to that when the nonvolatilematter of the flame-retardant coating agent for a vehicle seat accordingto the present invention is powderized in the case of a solid and 10 gof the nonvolatile matter of the flame-retardant coating agent for avehicle seat according to the present invention is then put in 100 g ofion-exchanged water at 20° C. and strongly shaken at 20° C.±0.5° C. for1 minute, the degree (g) to which the nonvolatile matter of theflame-retardant coating agent for a vehicle seat according to thepresent invention dissolves in 100 g of ion-exchanged water is 1.0 g orless. The “dissolve” as used herein may mean to give a transparentsolution or be transparently mixed in an arbitrary ratio.

(Process for Producing Flame-Retardant Vehicle Seat Material)

The process for producing a flame-retardant vehicle seat materialaccording to the present invention may not be particularly limited. Asthe preferable producing method, there may be used, for example, amethod of treating one surface of a vehicle seat material with theflame-retardant coating agent for a vehicle seat according to thepresent invention and then drying it to form a flame-retardant filmcontaining Compound (A) and Compound (C) (as desired, Compound (B)and/or Compound (D)) on the treated surface of the vehicle seat materialand/or in the vehicle seat material.

(Treatment of Vehicle Seat Material)

In the case of treating the vehicle seat material with theflame-retardant coating agent for a vehicle seat according to thepresent invention, the flame-retardant coating agent for a vehicle seataccording to the present invention may be used as it is or mayappropriately be diluted.

The method for treating the vehicle seat material with theflame-retardant coating agent for a vehicle seat according to thepresent invention may include: a coating method such as gravure coater,knife coater, roll coater, slit coater, comma coater, air knife coater,flow coater, brush, and foaming.

In the flame-retardant seat material for a vehicle seat according to thepresent invention, after treating the vehicle seat material with theflame-retardant coating agent for a vehicle seat, lamination or bondingmay also be performed.

The method for drying after the treatment of one surface of a vehicleseat material with the flame-retardant coating agent for a vehicle seataccording to the present invention may not be particularly limited, and,for example, dry drying using hot air; wet drying using ahigh-temperature steamer (H.T.S.) or a high-pressure steamer (H.P.S.);and a drier of microwave irradiation type, may be used. One of thesedrying methods may be used alone, or two or more thereof may also beused in combination, as desired. The drying temperature may preferablybe 80 to 180° C. and the drying time may preferably be 1 to 30 minutes.In particular, the drying temperature may preferably be 100 to 160° C.and the drying time may preferably be 1 to 10 minutes. By such drying, aflame-retardant film may be formed on the treated surface of the vehicleseat material and/or in the vehicle seat material.

As for the deposition amount (DRY) of the flame-retardant coating agentfor a vehicle seat with respect to the vehicle seat material, the totalof Compound (A), Compound (B), Compound (C) and Compound (D) maypreferably be 20 to 100 g/m², more preferably 40 to 80 g/m².

If the deposition amount (DRY) is less than 20 g/m², the flameretardancy may tend to be reduced, and if it exceeds 100 g/m², furtherimprovement of the flame retardancy may tend to be lessened.

The vehicle seat material that may be treated with the flame-retardantcoating agent for a vehicle seat according to the present invention maynot be particularly limited. Specific examples thereof may include: awoven fabric, a knitted fabric and a nonwoven fabric, each composed of anatural fiber such as cotton, hemp, hemp, silk and wool, a regeneratedfiber such as rayon, a semisynthetic fiber such as acetate, a syntheticfiber such as polyamide-based fiber, polyvinyl chloride-based fiber,polyacrylonitrile-based fiber, polyester-based fiber, polyurethane-basedfiber, polyethylene-based fiber and polypropylene-based fiber, or acomposite or mixed fiber thereof. Among others, in view of the flameretardancy and the effect of reducing water spotting, a woven ornonwoven fabric having a basis weight of 50 g/m² or more may bepreferred, and a woven fabric of 100 to 400 g/m² and a nonwoven fabricof 50 to 200 g/m² may be more preferred.

The vehicle seat material may be a material subjected to a dyeingtreatment or a soaping treatment.

(Quantitative Ratio)

In the present invention, a quantitative ratio in the following rangemay be preferred.

In the Compounds (A), (B), (C) and (D), (A):(C) may preferably be 1:9 to9.5:0.5, more preferably 3:7 to 9:1.

(A)+(B)+(D):(C) may preferably be 1:9 to 9.5:0.5, more preferably 3:7 to9:1.

(A):(B)+(D) may preferably be 1:0.1 to 15, more preferably 1:0.1 to 10.

(A):(B) may preferably be 1:0.1 to 10, more preferably 1:0.1 to 7.

(A):(D) may preferably be 1:0.1 to 10, more preferably 1:0.1 to 7.

(A)+(B):(C) may preferably be 3:7 to 9:1, more preferably 4:6 to 9:1.

(A)+(D):(C) may preferably be 3:7 to 9:1, more preferably 4:6 to 9:1.

EXAMPLES

Hereinbelow, the present invention will be described in more detail withreference to Examples and Comparative Examples. However, the presentinvention should not be limited to the following Examples.

Production Example 1

45 mass parts of resorcinol di-2,6-xylenyl phosphate, 5 mass parts of anethylene oxide 20-mol adduct of tristyrenated phenol (hereinafter,simply referred to as “TSP20E”), and 50 mass parts water were subjectedto a bead mill treatment, so as to obtain an emulsified/dispersed liquid(average particle size: 0.5 μm) of Compound (B). In the bead milltreatment, DYNO-MILL MULTI LAB Type (mechanical seal type) of Willy etBakkofen Inc., Ltd. was used.

Production Example 2

45 Mass parts of10-benzyl-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, 3 massparts of a sodium hydroxide neutralization product of TSP20E reactedwith chlorosulfonic acid (hereinafter, simply referred to as “TSP20ES),and 52 mass parts of water were subjected to a bead mill treatment toobtain an emulsified/dispersed liquid (average particle size: 0.5 μm) ofCompound (B).

Production Example 3

An emulsified/dispersed liquid (average particle size: 0.3 μm) ofCompound (B) was obtained by performing the operation in the same manneras in Production Example 1 except that biphenyl diphenyl phosphate wasused in place of resorcinol di-2,6-xylenylphosphate and a dispertreatment was performed in place of the bead mill treatment.

Production Example 4

An emulsified/dispersed liquid (average particle size: 0.3 μm) ofCompound (B) was obtained by performing the operation in the same manneras in Production Example 3 except that trixylenyl phosphate was used inplace of biphenyl diphenyl phosphate.

Synthesis Example 1 (Polycarbonate-Based Urethane Resin: PolyurethaneResin Having Anionic Group)

In a four-neck flask equipped with a stirrer, a reflux condenser tube, athermometer and a nitrogen blowing tube, 97.5 g of polyhexamethylenecarbonate diol (average molecular weight: 2,000), 7.2 g ofdimethylolbutanoic acid, 1.5 g of 1,4-butanediol, 0.005 g of dibutyltindilaurate, and 61.0 g of methyl ethyl ketone were placed and uniformlymixed, and 36.1 g of isophorone diisocyanate was then added and reactedat 80° C. for 180 minutes to obtain a methyl ethyl ketone solution of aurethane prepolymer having a free isocyanate group content of 2.9% withrespect to the nonvolatile matter content. This solution was neutralizedwith 4.8 g of triethylamine, transferred to another vessel,emulsified/dispersed using a disper blade while gradually adding 362 gof water at 30° C. or less, and after adding 14.5 g of an aqueous 20mass ethylenediamine solution, reacted for 90 minutes. Subsequently, thesolvent was removed from the obtained polyurethane resin dispersedliquid state at 50° C. under reduced pressure to obtain a polyurethaneresin water-emulsified/dispersed liquid wherein the nonvolatile mattercontent of the polyurethane resin was 30 mass %.

Synthesis Example 2 (Polycarbonate-Based Urethane Resin: Nonionic ForcedEmulsification Type)

In the same flask as used in Synthesis Example 1, 195 g ofpolyhexamethylene carbonate diol (average molecular weight: 2,000), 1.5g of 1,4-butanediol, 0.005 g of dibutyltin dilaurate, and 61.0 g ofmethyl ethyl ketone were placed and uniformly mixed, and 36.1 g ofisophorone diisocyanate was then added and reacted at 80° C. for 60minutes to obtain a methyl ethyl ketone solution of a urethaneprepolymer having a free isocyanate group content of 1.8% with respectto the nonvolatile matter content. This solution was transferred toanother vessel, and 19.6 g of TSP20E was charged thereinto at 30° C. orless. The resulting mixture was made uniform, then emulsified/dispersedusing a disper blade while gradually adding 501 g of water at 30° C. orless, and after adding 14.5 g of an aqueous 20 mass; ethylenediaminesolution, reacted for 90 minutes. Subsequently, the solvent was removedfrom the obtained polyurethane resin dispersed liquid state at 50° C.under reduced pressure to obtain a polyurethane resinwater-emulsified/dispersed liquid having a nonvolatile matter content of32.5 mass % (the nonvolatile matter content of the polyurethane resinwas 30 mass %).

Example 1

120 Mass parts of melamine cyanurate (trade name: MC-6000, averageparticle size: 2 μm, mfd. by Nissan Chemical Industries, Ltd.) as thecomponent (A), 266.7 mass parts (120 mass parts as the resorcinoldi-2,6-xylenyl phosphate) of the emulsified dispersion of ProductionExample 1 as the component (B), 200 mass parts (60 mass parts as thepolyurethane resin) of the polycarbonate-based urethane resinwater-emulsified/dispersed liquid obtained in Synthesis Example 1 as thecomponent (C), 17.5 mass parts (7 mass parts as the alkali thickeningtype acrylic resin) of NEOSTECKER V-500 (mfd. by Nicca Chemical Co.,Ltd.) as the thickener were put in a mixing pot and mixed while stirringto provide a uniform mixture, and the mixture was adjusted by addingwater and 25% aqueous ammonia so that the total of the Compounds (A) to(D) in the flame-retardant coating agent for a vehicle seat may be 30mass % and the pH may be 8.5, to obtain a flame-retardant coating agentfor a vehicle seat. In this flame-retardant coating agent for a vehicleseat, the average particle size was 2 μm, the viscosity was 10,000mPa·s, and the PVI value was 0.2.

Subsequently, one surface of a polyester plain-woven fabric (subjectedto dying and soaping) having a basis weight of 250 g/m² was treated withthe coating agent as stated above by using a knife coater to provide adeposition amount (DRY) of 50±5 g/m² and dried at 150° C. for 3 minutesto manufacture a flame-retardant vehicle seat material. The depositionamount was determined by calculation according to a formula of: {(massof flame-retardant vehicle seat material−mass of vehicle seatmaterial)}÷(area of cloth).

The obtained flame-retardant vehicle seat material was evaluated for thefire retardancy (flame retardancy), hot water spotting resistance, andseam fatigue-preventing property, and the results are shown in Table 1.

Examples 2 to 22 and 24 and Comparative Example 1, 3 and 4

Flame-retardant coating agents for a vehicle seat were obtained byperforming the operation in the same manner as in Example 1 except forchanging the component (A), the component (B), the component (C) andCompound (D) to those in the composition shown in Table 1 and makingadjustment so that the total of the Compounds (A) to (D) in theflame-retardant coating agent for a vehicle seat may be 30 mass % andthe pH may be 8.5. In all flame-retardant coating agents for a vehicleseat, the viscosity was 10,000 mPa·s, and the PVI value was 0.2. Theaverage particle size is shown in Tables 1 and 2.

Subsequently, flame-retardant vehicle seat materials of Examples 2 to 22and 24 and Comparative Examples 1, 3 and 4 were obtained by using theobtained coating agents and performing the operation in the same manneras in Example 1.

Example 23

The flame-retardant vehicle seat material of Example 23 was obtained byperforming the operation in the same manner as in Example 19 except fornot using a thickener.

In the obtained flame-retardant coating agent for a vehicle seat, theviscosity was 300 mPa·s, and the PVA value could not be measured.

These flame-retardant vehicle seat materials were evaluated for the fireretardancy (flame retardancy), hot water spotting resistance, and seamfatigue-preventing property, and the results are shown in Table 2. InExample 23, back-bleeding occurred to reduce the decorative property.

The results from evaluating the fire retardancy, hot water spottingresistance, and seam fatigue-preventing property on theseflame-retardant vehicle seat material are shown in Tables 1 and 2.

[Evaluation Method] 1. Measurement Method of Fire Retardancy (FlameRetardancy)

The burn rate was measured on 10 sheets in conformity with FMVSS-302(Federal Motor Vehicle Safety Standard). The average value (arithmeticmean value) of burn rates of 10 sheets was judged according to thefollowing criteria.

A: The average value of burn rates may be smaller than 50 mm/min, or theburn distance may be 50 mm or less and the time of burning may be within60 seconds.

In the case of self-extinguishing before benchmark, the burn rate cannotbe measured, and the number of occurrences may be indicated on the rightof mark A.

B: The average value of burn rates may be larger than 50 mm/min.

C: The average value of burn rates may be larger than 100 mm/min.

2. Method of Measuring Hot Water Spotting

The flame-retardant vehicle seat material was placed on 10 mm-thickurethane foam with the coating-treated surface down, and 5 ml of boileddistilled water was dropped thereon (on the surface opposite thecoating-treated surface of the flame-retardant vehicle seat material).After standing at room temperature for 16 hours, the hot water spottingwas judged according to the following criteria.

S: Spotting may be unrecognized, and the color tone in the wettedportion may not be changed.

A: Spotting and change of the color tone in the wetted portion may beslightly recognized.

B: Spotting may be clearly recognized, and the color tone in the wettedportion may be different from that in the non-wetted portion.

C: Powdering may be generated in the spotting.

3. Evaluation Method of Texture

The evaluation conformed to JIS L 1096 Method A (45° Cantilever Method).The texture was judged according to the following criteria.

H: A rating of “hard” may be assigned when 70 mm or more.

S: A rating of “soft” may be assigned when less than 70 mm and 40 mm ormore.

SS: A rating of “very soft” may be assigned when less than 40 mm.

4. Slimy Feel

Hot water (90° C.) was dropped in a diameter of 5 mm on thecoating-treated surface of the flame-retardant vehicle seat material,and the slimy feel was examined by tactile impression according to thefollowing criteria.

S: No slimy feel, and a water droplet may not penetrate into the coatingsurface.

A: No slimy feel.

B: Slimy feel may be slightly caused.

C: Strong slimy feel may be caused.

5. Seam Fatigue-Preventing Property

Two sheets of test fabric of 10 cm (longitudinal direction)×10 cm(transverse direction) were sampled from the flame-retardant vehicleseat material. The non-coating-treated surfaces of two test fabricsheets were overlapped and stitched with a sewing machine at a pitch of5 mm at the position of 1 cm from the end of one side in thelongitudinal direction to produce a specimen to be tested in thetransverse direction. The specimen was opened, one end of the specimenwas fixed to a seam fatigue testing machine (manufactured by YamaguchiKagaku Sangyo), a load of 3 kgf was applied to another end, and a seamfatigue test was repeated 2,500 times.

Thereafter, in the state of the load being applied, the size of a seam(needle hole) was measured in units of 0.1 mm on 10 holes.

A test was similarly performed also in the longitudinal direction, andthe values of 20 holes in the longitudinal and transverse directionswere averaged. The preventing property was judged according to thefollowing criteria.

A: The average size of seams (needle holes) may be 1.9 mm or less.

B: The average size of seams (needle holes) may be more than 1.9 mm and2.2 mm or less.

C: The average size of seams (needle holes) may be more than 2.2 mm.

6. Wet Seam Fatigue-Preventing Property

This preventing property was judged according to the same criteria byperforming the same test as in the seam fatigue-preventing propertyexcept that the specimen prepared in “5. Seam Fatigue-PreventingProperty” as stated above was moisturized by immersing it in 200 ml ofion-exchanged water at 45±5° C. and then squeezed to a pickup of 100%.

7. Viscosity

200 ml of the flame-retardant coating agent for a vehicle seat was putin a vial with an inner diameter of 50 mm and measured by means of aB-type viscometer (high viscosity type, Tokimec Inc., BH-typeviscometer, Rotor No. 5, 20 rpm, measurement temperature: 20° C.)

TABLE 1 Composition of Flame- Example Retardant Processing Agent 1 2 3 45 6 7 8 Compound A Melamine cyanurate 120 85 60 45 38 45 45 34.5Compound B Production Example 1 120 85 60 45 38 45 34.5 ProductionExample 2 45 Production Example 3 Production Example 4 Ammoniumpolyphosphate: *1 Compound C Synthesis Example 1 60 130 92 69 58 69 90Acrylic resin: *2 69 Compound D Aluminum hydroxide: *3 88 140 166 140140 140 A:B 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 A:B:C 8:2 5.7:4.3 5.7:4.35.7:4.3 5.7:4.3 5.7:4.3 5.7:4.3 4.3:5.7 D/A + B + D: *5 0 0 42 61 69 6161 67 Amount of activator: *6 4.4 3.1 2.2 1.7 1.4 1.0 2.7 2.1 Averageparticle 2 2 7 7 7 7 7 7 diameter (μm) Flame retardancy A9 A9 A9 A7 A7A7 A2 A2 Hot water spotting A S S S S S S S Texture H H H H H H S HSlime S S S S S S S S Seam fatigue- A A A A B A A A preventing propertyWet seam fatigue A A A A B A A A Composition of Flame- Example RetardantProcessing Agent 9 10 11 12 13 14 15 Compound A Melamine cyanurate 67.552 15 52 45 50 50 Compound B Production Example 1 22.5 15 15 ProductionExample 2 22.5 15 Production Example 3 Production Example 4 15 Ammoniumpolyphosphate: *1 22.5 38 75 38 10 10 Compound C Synthesis Example 1 6969 69 69 69 69 Acrylic resin: *2 69 Compound D Aluminum hydroxide: *3140 140 140 140 140 140 140 A:B   1:0.33   1:0.73 1:5   1:0.73 1:1  1:0.8   1:0.8 A:B:C 5.7:4.3 5.7:4.3 5.7:4.3 5.7:4.3 5.7:4.3 5.7:4.35.7:4.3 D/A + B + D: *5 61 61 61 61 61 61 61 Amount of activator: *6 0.00.0 0.0 0.0 1.4 0.9 0.9 Average particle 18 18 18 18 7 18 18 diameter(μm) Flame retardancy A4 A8 A8 A4 A7 A8 A8 Hot water spotting A A B B SS S Texture H H H S H H S Slime A A B B S S S Seam fatigue- A A A A A AA preventing property Wet seam fatigue A A B C A A A

TABLE 2 Composition of Flame- Example Retardant Processing Agent 16 1718 19 20 21 22 Compound A Melamine cyanurate 81 63 63 78.5 118 27 78.5Compound B Production Example 1 81 63 Production Example 2 ProductionExample 3 63 Production Example 4 78.5 39 130 78.5 Ammoniumpolyphosphate: *1 Compound C Synthesis Example 1 52 39 39 25 25 25Synthesis Example 2 25 Acrylic resin: *2 Compound D Aluminum hydroxide:*3 86 134 134 118 118 118 118 A:B 1:1 1:1 1:1 1:1   1:0.33   1:4.8 1:1A + B:C 7.6:2.4 7.6:2.4 7.6:2.4 8.6:1.4 8.6:1.4 8.6:1.4 8.6:1.4 D/A +B + D: *5 35 52 52 43 43 43 43 Amount of activator: *6 3.0 2.3 2.3 2.91.4 4.8 3.6 Average particle 7 7 7 7 7 7 7 diameter (μm) Flameretardancy A8 A8 A7 A9 A7 A7 A9 Hot water spotting S S S S S A A TextureH H SS SS S SS SS Slime S S S S S S S Seam fatigue- A A A A A A Apreventin property Wet seam fatigue A A A A A A A ComparativeComposition of Flame- Comparative Example Retardant Processing AgentExample 1 Example 24 3 4 Example 23 Compound A Melamine cyanurate 17178.5 Compound B Production Example 1 171 20 Production Example 2 47Production Example 3 Production Example 4 78.5 Ammonium polyphosphate:127 175 *1 Compound C Synthesis Example 1 129 129 127 25 SynthesisExample 2 Acrylic resin: *2 106 Compound D Aluminum hydroxide: *3 118A:B 0:1 1:0 0:1 0:1 1:1 A + B:C 5.7:4.3 5.7:4.3 5.8:4.2 6.5:3.5 8.6:1.4D/A + B + D: *5 0 0 0 0 43 Amount of activator: *6 6.3 0.0 1.0 0.7 2.9Average particle 0.5 2 18 18 7 diameter (μm) Flame retardancy B B A8 A2A9 Hot water spotting A A C C S Texture H H H S S Slime S S B C S Seamfatigue- A A C C A preventin property Wet seam fatigue A A C C A *1:Trade name: FRCROS 486, ammonium polyphosphate surface-treated with asilane coupling agent, average particle size: 18 μm, mfd. by Budenheim*2: Trade name: ARON A-104, mfd. by Toagosei Co., Ltd., the solidcontent is 40% and therefore, the value of solid content is shown in theTable. *3: Trade name: B103, average particle size: 7 μm, mfd. by NipponLight Metal Company, Ltd. *4: NEOSTECKER V-500 (mfd. by Nicca ChemicalCo., Ltd.) *5: Amount (mass %) of D with respect to the total of A + B +D *6: Amount (mass parts) of activator per 100 mass parts of the totalof A to D

Example 25

340 Mass parts of melamine cyanurate (trade name: MC-6000, averageparticle size: 2 μm, mfd. by Nissan Chemical Industries, Ltd.) as thecomponent (A), 200 mass parts (60 mass parts as the polyurethane resin)of the polycarbonate-based urethane resin water-emulsified/dispersedliquid obtained in Synthesis Example 1 as the component (C), 17 massparts (6 mass parts as the alkali thickening type acrylic resin) ofNEOSTECKER V-500 (mfd. by Nicca Chemical Co., Ltd.) as the thickenerwere put in a mixing pot and stirred to provide a uniform mixture, andthe mixture was adjusted by adding 25% aqueous ammonia and water so thatthe total of the Compounds (A) to (D) in the flame-retardant coatingagent for a vehicle seat may be 40 mass % and the pH may be 8.5, toobtain a flame-retardant coating agent for a vehicle seat. In thisflame-retardant coating agent for a vehicle seat, the average particlesize was 2 μm, the viscosity was 10,000 mPa·s, and the PVI value was0.2.

Subsequently, one surface of a polyester plain-woven fabric (subjectedto dying and soaping) having a basis weight of 200 g/m² was treated withthe coating agent as stated above by using a knife coater to provide adeposition amount (DRY) of 65±5 g/m² and dried at 150° C. for 3 minutesto manufacture a flame-retardant vehicle seat material. The depositionamount was determined by calculation according to a formula of: {(massof flame-retardant vehicle seat material−mass of vehicle seatmaterial)}÷(area of cloth).

The obtained flame-retardant vehicle seat material was evaluated for thefire retardancy (flame retardancy), hot water spotting resistance, andseam fatigue-preventing property, and the results are shown in Table 3.

Examples 26 to 35 and Comparative Example 5 to 8

Flame-retardant coating agents for a vehicle seat were obtained byperforming the operation in the same manner as in Example 1 except forchanging the component (A), the component (B), the component (C) andCompound (D) to those in the composition shown in Table 1 and makingadjustment so that the total of the Compounds (A) to (D) in theflame-retardant coating agent for a vehicle seat may be 40 mass % andthe pH may be 8.5. In all flame-retardant coating agents for a vehicleseat, the viscosity was 10,000 mPa·s, and the PVI value was 0.2. Theaverage particle size is shown in Tables 3 and 4.

Subsequently, flame-retardant vehicle seat materials of Examples 26 to35 and Comparative Examples 5 to 8 were obtained by using the obtainedcoating agents and performing the operation in the same manner as inExample 1.

These flame-retardant vehicle seat materials were evaluated for the fireretardancy (flame retardancy), hot water spotting resistance, and seamfatigue-preventing property, and the results are shown in Tables 3 and4.

TABLE 3 Example 25 26 27 28 29 30 31 32 33 34 35 Compound A Melaminecyanurate 340 290 170 68 136 85 228 182 75 56 23 Compound B ProductionExample 1 34 85 153 114 205 Production Example 2 46 Compound C SynthesisExample 1 60 60 60 60 60 60 172 172 172 60 172 Compound D Aluminumhydroxide: 0 50 170 272 170 170 0 0 0 170 0 *3 A:B + D 1:0   1:0.17 1:11:4   1:1.5 1:3 1:0   1:0.25 1:2 1:5 1:9 A + B + D:C 8.5:1.5 8.5:1.58.5:1.5 8.5:1.5 8.5:1.5 8.5:1.5 5.7:4.3 5.7:4.3 5.7:4.3 8.5:1.5 5.7:4.3D/A + B + D *5 0 14.7 50 80 50 50 0 0 0 50 0 Amount of activator 0 0 0 00.9 2.4 0 0.8 4.3 3.2 5.7 *6 Average particle 2 7 7 7 7 7 2 2 2 7 2diameter (μm) Flame retardancy A3 A5 A8 A4 A8 A8 A2 A8 A7 A7 A3 Hotwater spotting A A A A A A A A A A A Texture H H H H H H H H H H H SlimeS S S S S S S S A A A Seam fatigue- A A A A A A A A A A A preventingproperty Wet seam fatigue A A A A A A A A A A A

TABLE 4 Comparative Comparative Comparative Comparative Example 5Example 6 Example 7 Example 8 Compound A Melamine cyanurate 0 0 0 0Compound B Production Example 1 228 Production Example 2 62 ProductionExample 3 170 Ammonium 169 polyphosphate*1 Compound C Synthesis Example1 60 60 169 172 Compound D Aluminum 340 170 0 0 hydroxide: *3 A:B + D0:1 0:1 0:1 0:1 A + B + D:C 8.5:1.5 8.5:1.5 5.8:4:2 5.7:4.3 D/A + B + D*5 100 50 0 0 Amount of 0 4.7 1.0 6.3 activator *6 Average particle 7 718 0.5 diameter (μm) Flame retardancy C A2 A8 B Hot water spotting A A CA Texture H SS H H Slime S A B A Seam fatigue- A C C A preventingproperty Wet seam fatigue A C C A

As described in Examples and Comparative Examples as stated above, whena specific nitrogen-containing compound and a specific phosphorus-basedcompound were used in combination, good results that sufficient flameretardancy (which cannot be achieved by conventional techniques) equalto or greater than that of APP is developed and occurrence of waterspotting by hot water is suppressed, were obtained. In addition, it wasconfirmed that those compounds have no adverse effect on the seamfatigue.

In the flame-retardant coating agent for a vehicle seat according to thepresent invention, the amount used of a phosphorus-based compound thatis expensive in general may be reduced, and the cost may be savedwithout deteriorating the performance, so that the flame retardancy mayalso be enhanced by increasing the amount of the compound used. Further,since the amount of the phosphorus-based compound used may be reduced,the wastewater problem due to phosphorus may be alleviated.

In addition, in the present invention, arbitrary texture may be obtainedby using the phosphorus-based compound properly.

The quantitative ratios of respective components A to D in each ofExamples and Comparative Examples as stated above are shown together inTables 5 and 6 below.

A:(B+D)

(A+B+D):C

A:C

A:D

(A+D):C

TABLE 5 Example Example Example Example Example Example Example Example1 2 3 4 5 6 7 8 A:B + D 1:1 1:1   1:2.5   1:4.1   1:5.4   1:4.1   1:4.1  1:5.1 A + B + D:C 8:2 5.7:4.3 6.9:3.1 7.7:2.3 8.1:1.9 7.7:2.3 7.7:2.37:3 A:C 6.7:3.3 4:6 4:6 4:6 4:6 4:6 4:6 2.8:7.2 A:D 1:0 1:0   1:1.5  1:3.1   1:4.4   1:3.1   1:3.1   1:4.1 A + D:C 6.7:3.3 4:6 6.2:3.87.3:2.7 7.8:2.2 7.3:2.7 7.3:2.7 6.6:3.4 Example Example Example ExampleExample Example Example 9 10 11 12 13 14 15 A:B + D   1:2.4   1:3.4  1:14.3   1:3.4   1:4.1   1:3.6   1:3.6 A + B + D:C 7.7:2.3 7.7:2.37.7:2.3 7.7:2.3 7.7:2.3 7.7:2.3 7.7:2.3 A:C 4.9:5.1 4.3:5.7 1.7:8.34.3:5.7 4:6 4.2:5.8 4.2:5.8 A:D   1:2.1   1:2.7   1:9.3   1:2.7   1:3.1  1:2.8   1:2.8 A + D:C 7.5:2.5 7.4:2.6 6.9:3.1 7.4:2.6 7.3:2.7 7.3:2.77.3:2.7

TABLE 6 Example Example Example Example Example Example Example 16 17 1819 20 21 22 A:B + D   1:2.1   1:3.1   1:3.1   1:2.5   1:1.3   1:9.2  1:2.5 A + B + D:C 8.3:1.7 8.7:1.3 8.7:1.3 9.2:0.8 9.2:0.8 9.2:0.89.2:0.8 A:C 6.1:3.9 6.2:3.8 6.2:3.8 7.6:2.4 8.3:1.7 5.2:4.8 7.6:2.4 A:D  1:1.1   1:2.1   1:2.1   1:1.5 1:1   1:4.4   1:1.5 A + D:C 7.6:2.48.3:1.7 8.3:1.7 8.9:1.1 9:1 8.5:1.5 8.9:1.1 Comparative ExampleComparative Comparative Example Example 1 24 Example 3 Example 4 23A:B + D 0:1 1:0 0:1 0:1   1:2.5 A + B + D:C 5.7:4.3 5.7:4.3 5.8:4.26.5:3.5 9.2:0:8 A:C 0:1 5.7:4.3 0:0 0:1 7.6:2.4 A:D 0:0 1:0 0:0 0:0  1:1.5 A + D:C 0:1 5.7:4.3 0:1 0:1 8.9:1.1

INDUSTRIAL APPLICABILITY

The flame-retardant coating agent for a vehicle seat according to thepresent invention may be useful, because its use may make it possible toobtain a high-quality flame-retardant vehicle seat material havingsufficient fire resistance conformed to “FMVSS-302” speculated by theFederal Motor Vehicle Safety Standard or “JIS D1201” specified in theJapanese Industrial Standards and being prevented from occurrence ofwater spotting by hot water.

1. A flame-retardant coating agent for a vehicle seat, comprising: (A) anitrogen-comprising: compound and (C) an aqueous thermoplastic resin. 2.A flame-retardant coating agent for a vehicle seat, comprising: (A) anitrogen-containing compound, (C) an aqueous thermoplastic resin, (B) aphosphorus-based compound, and/or (D) a metal hydroxide.
 3. Theflame-retardant coating agent for a vehicle seat according to claim 1,wherein Compound (A) is at least one kind selected from the groupconsisting of melamine compounds, triazine compounds, and a salt thereofwith (iso)cyanuric acid.
 4. The flame-retardant coating agent for avehicle seat according to claim 2, wherein Compound (B) is at least onekind selected from the group consisting of the compounds represented bythe following formulae (1) to (5) and a polyphosphoric acid compound andCompound (D) is at least one kind selected from the group consisting ofaluminum hydroxide, magnesium hydroxide and calcium hydroxide: Formula(1):

(wherein each of R¹ and R² independently represents a phenyl group thatmay have an alkyl group having a carbon number of 1 to 4, a naphthylgroup that may have an alkyl group having a carbon number of 1 to 4, ora biphenyl group that may have an alkyl group having a carbon number of1 to 4, E represents a direct bond, —O— or —N(H)—, “a” represents 1 or2, and b represents 0 or 1); Formula (2)

(wherein R³ represents a benzyl group, a methylbenzyl group, a phenethylgroup, a naphthylmethyl group, or a group represented by the followingformula (6)): Formula (6):

(wherein R⁴ represents an alkyl group having a carbon number of 1 to 10,a phenyl group, or a benzyl group); Formula (3):

(wherein each of R⁵ to R⁸ independently represents a phenyl group thatmay have an alkyl group having a carbon number of 1 to 4, R⁹ representsan arylene group that may have a substituent, and c represents aninteger of 1 to 5); Formula (4):

(wherein each of R¹⁰ and R¹¹ independently represents an alkyl grouphaving a carbon number of 1 to 4, and R¹² represents a biphenyl group ora naphthyl group); and Formula (5):

(wherein each of R¹³ to R¹⁶ independently represents an alkyl grouphaving a carbon number of 1 to 4).
 5. The flame-retardant coating agentfor a vehicle seat according to claim 1, wherein Compound (C) is apolyurethane resin having an anionic group.
 6. The flame-retardantcoating agent for a vehicle seat according to claim 2, wherein themixing ratio (A):{(B)+(D)} of Compound (A) to the total of Compound (B)and Compound (D) is, in mass ratio, 1:0.1 to 15 and the mixing ratio{(A)+(B)+(D)}:(C) of the total of Compound (A), Compound (B) andCompound (D) to Compound (C) is, in mass ratio, 1:9 to 9.5:0.5.
 7. Aprocess for producing a flame-retardant vehicle seat material,comprising treating one surface of a vehicle seat material with theflame-retardant coating agent for a vehicle seat according to claim 1and then drying it to form a flame-retardant film comprising: Compound(A) and Compound (C) on the treated surface of the vehicle seat materialand/or in the vehicle seat material, to thereby obtain a flame-retardantvehicle seat material.
 8. A process for producing a flame-retardantvehicle seat material, comprising treating one surface of a vehicle seatmaterial with the flame-retardant coating agent for a vehicle seataccording to claim 2 and then drying it to form a flame-retardant filmcomprising: Compound (A), Compound (C), Compound (B) and/or Compound (D)on the treated surface of the vehicle seat material and/or in thevehicle seat material, to thereby obtain a flame-retardant vehicle seatmaterial.